Man Brake System and Air Suspension

Brake System and Air
Suspension
to EC Directives
Forward-control Vehicles, Heavy Range
TG-A
2002 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12
Publication no.: Repair Manual

81.99198-6032 2nd edition P 85
MAN Nutzfahrzeuge Aktiengesellschaft Reparaturanleitung P 85

Dachauer Str. 667 oder Postfach 50 06 20 Brems- und Luftfederungsanlage
80995 MNCHEN 80976 MNCHEN Frontlenker Schwere Reihe TG-A
- englisch -
Printed in Germany
Repair Manual P 85
2nd edition
Brake System and Air Suspension

to EC Directives
Trucknology Generation A (TG-A)
81.99198-6032
We reserve the right to make modifications in the course of further development.
2002 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, copying or translation, even of extracts, is not allowed without written permission from MAN. All
rights under the copyright law are strictly reserved by MAN.
VSWD 1/TG 10. 2002 bersetzung + Satz: emes GmbH Druck: MAN-Werksdruckerei
Friedrichshafen
1.10 - 2 RA - P 85
TABLE OF CONTENTS
Contents Section
Title page/printer's imprint ............................................................................................................... 1.10-1

Table of contents ............................................................................................................................. 1.20-1
Notes on safety................................................................................................................................ 1.30-1
List of abbreviations......................................................................................................................... 1.32-1
References to other brake/repair manuals ...................................................................................... 1.32-2
New features/modifications, TG-A brake system and new devices ................................................ 1.33-1
Functional description, electronically controlled air management (ECAM) ..................................... 1.40-1
Description, brake circuit function ................................................................................................... 1.41-1
Description, ECAM with back-up pressure regulator ...................................................................... 1.42-1
Software parameters and ECU function sequences ....................................................................... 1.43-1
Description, electronic brake system (EBS) .................................................................................... 1.50-1
Description, EBS - function circuits ................................................................................................. 1.51-1
Description, EBS - operation ........................................................................................................... 1.52-1
Description, EBS - specific components ......................................................................................... 1.53-1
EBS - operating notes and instructions ........................................................................................... 1.54-1
Function, EBS control unit ............................................................................................................... 1.55-1
Function, service brake valve with brake power sensor.................................................................. 1.55-4
Function, 1-channel pressure control module ................................................................................. 1.55-5
Function, 2-channel pressure control module ................................................................................. 1.55-6
Function, trailer control module ....................................................................................................... 1.55-7
Function, ALB sensor for vehicles with leaf and air suspension ..................................................... 1.55-8
Function, rpm sensor....................................................................................................................... 1.55-9
Function, brake wear sensor ........................................................................................................... 1.55-10
Description, reservoir and brake circuits ......................................................................................... 1.61-1
Functional description, brake system .............................................................................................. 1.61-2
Reservoir and brake circuit failures ................................................................................................. 1.62-1
Testing the brake system ................................................................................................................ 1.62-4
Testing the braking effect ................................................................................................................ 1.62-5
Overview of installation diagrams, 2/3/4-axle trucks, 18/41 t GVW with disc brakes on front axle
and rear axle.................................................................................................................................... 1.70-1
Installation diagrams........................................................................................................................ 1.71
Function diagrams ........................................................................................................................... 2.20-1

Overview of function diagrams, 2-axle trucks, 18/20 t GVW with disc brakes on front axle and
rear axle........................................................................................................................................... 2.20-3
Function diagrams ........................................................................................................................... 2.21
Overview of function diagrams, 3-axle trucks, 24/26 t GVW with disc brakes on front axle,
leading axle, trailing axle and rear axle ........................................................................................... 2.50-1
Overview of function diagrams, 3-axle trucks (FVL, FDL, FDA) with front, leading/trailing and
rear axle, 24 to 41 t GVW with disc brakes, disc/drum brakes and drum brakes .......................... 3.10-1
Function diagrams ........................................................................................................................... 3.11
Overview of function diagrams, 4-axle trucks (VF/VFL) with leading/trailing axle, 32 to 50 t GVW
with disc/drum brakes ..................................................................................................................... 3.50-1
Supplementary function diagrams................................................................................................... 5.00-1

Overview of supplementary function diagrams ............................................................................... 5.10-1
Additional function diagrams ........................................................................................................... 5.11
Installation and function diagrams, air suspension ......................................................................... 6.00-1

Overview of installation diagrams.................................................................................................... 6.10-1
Installation diagrams........................................................................................................................ 6.11
Overview of function diagrams, air suspension............................................................................... 6.50-1

Design, electronic level control........................................................................................................ 6.50-2
Air spring function diagrams ............................................................................................................ 6.51-1
RA - P 85 1.20 - 1
TABLE OF CONTENTS
Contents Section
Plastic pipes, VOSS - plug connections/screw connections ............................................................ 7.00-1

Repair, plastic pipes/plug connections/screw connections .............................................................. 7.10
Brake units, design/function ............................................................................................................. 8.00-1

Multi-circuit protection valve............................................................................................................. 8.10-1
Service brake valve .......................................................................................................................... 8.23-1
Diaphragm cylinder G 10. ................................................................................................................ 8.26-1
Combination brake cylinder G 11..................................................................................................... 8.30-1
Pressure sensor (EBS) .................................................................................................................... 8.69-1
Pressure control module, 1-channel PCM (EBS)............................................................................. 8.73-1
Pressure control module, 2-channel PCM (EBS)............................................................................. 8.74-1
Solenoid valve, ECAS ..................................................................................................................... 8.78-1
Position sensor, ECAS ..................................................................................................................... 8.79-1
Technical data, special tools ............................................................................................................ 9.00-1

Technical data .................................................................................................................................. 9.10-1
Special tools ..................................................................................................................................... 9.15-1
1.20 - 2 RA P 85
SAFETY REGULATIONS
1.30 Safety regulations
General
Working with trucks, buses and the accompanying service products should not pose any problems if
operators, maintenance personnel and repair staff receive suitable training and actively adopt a
thoughtful approach.
The following sections include summaries of important regulations listed according to major topics. The
intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution. Please note that these are merely brief extracts taken from various accident
prevention regulations and that they are in no way intended to replace such regulations.
Additional danger warnings appear in the manuals whenever potential risks are involved.
Important:
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves
skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into
eyes, etc.
1. Regulations for preventing accidents leading to injury to personnel.
Only authorised technical personnel are entitled to perform inspection,
adjustment and repair work.
Use wheel chocks to prevent the vehicle from rolling away.
Secure units during their removal.
Support the frame when working on the pneumatic or spring suspension system.
Work performed on the brake system:

Perform visual, function and effectiveness checks on the brake system after carrying
out any work on it whatsoever. These checks must be made in accordance with the
relevant safety inspection directive ( 29 of the statutory regulations governing
special brake inspections in the FRG).
Use a suitable testing system (e.g. MAN-cats) to check that EBS/ABS/ASR systems
function correctly.
Collect any hydraulic/brake fluid that leaks out.

Hydraulic/brake fluid is toxic! Do not allow it to come into contact with food or open
wounds.
Treat hydraulic/brake fluid as hazardous waste! Comply with the safety regulations
for preventing environmental pollution.
Only authorised personnel are permitted to start and operate an engine.

Do not approach moving parts of a running engine too closely. Do not wear baggy
clothing. Ensure adequate ventilation if you are working in enclosed spaces.
Do not touch units with your bare hands when they are at operating temperature:
Danger of burns! Always wear protective gloves when changing oil (in units at
operating temperature) in particular.
Do not open the coolant circuit until the engine has cooled down.
Keep units, ladders, steps, gangways and the areas around them free of oil and
grease. Accidents caused by slipping can have very serious consequences.
Only use tools that are in perfect condition. Worn-out spanners can slip: Risk of
injury!
No-one is allowed to stand under a unit suspended from a crane hook. Keep all
lifting tackle in good condition.
Do not attempt to tighten, loosen or open pipelines and hoses (e.g. in lubrication
circuit, coolant circuit and hydraulic oil circuit) whilst they are pressurised: Fluid
spraying out represents an injury hazard!
Do not hold your hands under the jet of fuel when checking the injector nozzles. Do
not inhale fuel vapours.
RA - P 85 1.30 - 1
SAFETY REGULATIONS
Always disconnect the batteries before working on the electrical system.

Disconnect the earth cable first of all, reconnect the earth cable last of all
Important! Battery gases are explosive. Oxyhydrogen gas may form in enclosed
battery boxes. Take particular care after long journeys or after charging the batteries
with a battery charger. When the batteries are disconnected, this gas may be ignited by
sparks produced by other continuously operating consumers, the tachograph etc. that
cannot be shut down. Blow compressed air through the battery box before
disconnecting the batteries!
Only tow-start the vehicle if the batteries are connected (minimum charge 40%)! Do
not use a boost-charger to jump-start the vehicle! Always disconnect the positive
and negative leads before boost-charging batteries!
Take care to avoid short circuits due to incorrect polarity or metal objects (spanners,
pliers etc.) left on the battery terminals.
Disconnect the batteries or recharge them every 4 weeks if the vehicle is not in use.
Caution! Battery acid is poisonous and corrosive. Wear suitable protective clothing
(gloves) when handling batteries. Do not tip or tilt batteries as acid may emerge.
Measure voltage only using a suitable measurement device! The input resistance of
the measurement device must be at least 10 M.
The ignition must be switched off before the wiring harness plugs of the electronic
control units are disconnected or connected up!
When performing electric welding work
Connect up the "ANTIZAP SERVICE MONITOR" protective device (MAN item number
80.78010.0001) in accordance with the instructions supplied with the device.
If this device is not available, disconnect the batteries and join the positive cable to
the negative cable in order to make a conductive connection.
Always earth the welding equipment as close as possible to the welding area. Do not
lay the cables to the welding equipment in parallel to electrical cables in the vehicle.
The chassis is not intended for use as an earth return! If attachments are to be fitted
to the vehicle (e.g. a wheelchair lift), additional earth (ground) lines with an
adequate cross-section must be fitted as well. Otherwise the earth connection may
be created along wire cables, wiring harnesses, gearbox shafts, gears etc. Severe
damage could result.
Plastic tubes (polyamide)
Important! Danger of damage and fire!
The warning sign opposite is attached to the inside of the diesel fuel or heating oil
tank flap. It warns you against welding or drilling near to plastic tubes.
If paint spraying is to be carried out, do not expose the electronic components to

high temperatures (max. 95 C) for more than brief periods; a time of up to 2 hours is
permissible at a maximum of 85 C. Disconnect the b atteries.
When the cab is tilted
Keep the tilting area in front of the cab clear
Stay out of the area between the cab and the chassis while the cab is being tilted!
Danger zone!
Always tilt the cab past the tilting point to its final position
Use the universal cab support when working while the cab is tilted
Air-conditioning system
Refrigerants and refrigerant vapours represent a health hazard. Avoid direct contact
and protect your hands and eyes at all times.
Do not drain gaseous refrigerants in enclosed areas.
Never mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant
1.30 - 2 RA - P 85
SAFETY REGULATIONS
2. Guidelines for preventing damage and premature wear on major components (engines, axles,
gearboxes, etc.)
Only load units in accordance with their specified and intended use. Do not overload!
If a fault occurs during operation, determine its cause immediately and correct the problem before it can
get any worse!
Clean units thoroughly before starting to repair them. Ensure that no dirt, sand or foreign objects can
get into the units whilst carrying out repairs.
Always use genuine spare parts. Fitting "equivalent parts" made by other companies can lead to severe
damage, and the workshop that did the work will be responsible for it. See the section entitled "Limited
liability for accessories and parts".
Never run units dry, i.e. always make sure that they have been filled with oil before running them.
Never run engines that have not been filled with coolant beforehand.
Use a suitable information sign to clearly indicate units that are not ready to be operated.
Only use service products (engine and gearbox oil as well as antifreeze and anti-corrosion protection)
that have been approved by MAN. Ensure cleanliness in all work.
Comply with specified maintenance intervals
Do not fill engine/gearbox oil above the maximum level mark. Do not exceed the maximum
permitted operational tilt.
Severe unit damage could result from non-compliance with these rules.
3. Limited liability for accessories and parts
In your own interests, you are recommended to use only accessories expressly approved by MAN and
genuine MAN parts. The reliability, safety and suitability of these parts and accessories have been determined
specifically for MAN vehicles. Despite constant market observation, we cannot judge the aspects of other
products, nor can we accept responsibility for them even if they have been officially approved by the German
TV technical inspection authorities or some other official body.
Attachments and special bodies

Comply with the safety instructions and regulations issued by the body manufacturer in question if
attachments or special bodies are fitted.
Taking out of operation or putting into storage

The special measures described in MAN Works Standard M 3069 Part 3 apply if buses or trucks are to be
withdrawn from service or stored for a period longer than 3 months.
RA - P 85 1.30 - 3
SAFETY REGULATIONS
4. Regulations for preventing damage to health and the environment:
Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority
when disposing of used coolant (mixture of antifreeze and water).
Cleaning the cooling circuit

Do not pour cleaning fluids and rinsing water down the drain if this practice is restricted by specific local
regulations. However, the cleaning fluid and rinsing water must, in all cases, be passed through an oil
separator with a sludge trap.
Cleaning the filter element

When blowing compressed air through the filter element, make sure the filter dust is collected by a vacuum
or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear suitable rubber
gloves or use a skin barrier cream when washing out the element, because cleaning agents have
aggressive grease-dissolving characteristics.
Engine/gearbox oil, filter cartridges, box-type filters, filter elements, desiccant cartridges
Only dispose of used oil at an approved collection point or depot. It is extremely important that oil is not
poured down the drain or onto the ground since it can pollute drinking water! Filter elements, cartridges and
box-type filters (oil and fuel filters, desiccant cartridges for the air dryer) are classified as hazardous waste
materials and must be disposed of properly. Please follow the instructions issued by the relevant local
authority.
Used engine/gearbox oil

Lengthy or repeated skin contact with any type of engine/gearbox oil removes grease from the skin. This
can cause dry skin, irritation or skin inflammation. In addition to these hazards, used engine oil contains
dangerous materials which have been shown to have a carcinogenic effect in animal skin tests. However,
used oils are not regarded as a health hazard provided that the basic rules of work safety and hygiene are
complied with.
Health protection precautions

Avoid lengthy, excessive or repeated skin contact with used oils.
Protect your skin using a suitable skin protection agent or protective gloves.
Clean areas of skin which have come into contact with engine oil.
- Wash the areas thoroughly with soap and water.
- A nailbrush enables more effective cleaning.
- Special cleaning agents make it easier to clean dirty hands.
- Do not use petrol, diesel oil, gas oil, thinners or solvents.
Apply a moisturising skin cream after cleaning your skin.
Change out of clothing or shoes which have become soaked with oil.
Never put oil-soaked rags into your clothing pockets.
Take care to dispose of used engine/gearbox oil properly.

Oils can damage groundwater quality
Therefore, never pour used oil onto the ground, into water or down the drains or sewers. Failure to comply
with these instructions can lead to prosecution.
Collect and dispose of used oil carefully. Contact the point of sale, supplier or your local authority for
information about collection depots.
Extract from "Information on dealing with used engine oil"

Auszug aus "Merkblatt fr den Umgang mit gebrauchtem Motorl"
The Mineral Oil Traders Association (MINERALLWIRTSCHAFTSVERBAND E.V)
Steindamm 71, D-20099 Hamburg, Germany
1.30 - 4 RA - P 85
SAFETY REGULATIONS
5. Working on brake pads, brake linings and similar parts
Harmful dust may be released when brake pads or linings are reworked in particular when they are
skimmed or ground and when wheel brakes are blown out.
Please take the necessary precautionary measures and observe the following safety advice to avoid
possible damage to your health:
If possible, carry out the work in question in the open or in an area equipped with an efficient ventilation
system!
If possible, use hand-operated or slow-running tools, equipped with a dust-collector if required!

Fast-running tools should always be fitted with such devices.
If possible, wet the workpiece prior to cutting or drilling!
Dispose of brake pads or linings as hazardous waste in an environmentally sound manner!
RA - P 85 1.30 - 5
LIST OF ABBREVIATIONS
ABS : Anti-lock brake system

ALB : Automatic load-dependent brake
ASM : Trailer control module
ASR : Anti-spin regulator
ASV : Trailer control valve
BA : Operator's manual
BBA : Service brake system
BBV : Service brake valve
BL : Leaf/air (suspension)
BLL : Leaf/air/air (suspension), e.g. in vehicles with a trailing axle
BO : Bosch (manufacturer)
BV : Vehicle construction regulations
BVA : Brake wear indicator
BVS : Brake wear sensor
BWG : Brake power sensor
CAN : Controller area network (bus system)
DBA : Auxiliary brake system
DBR : Auxiliary brake relay
DF : Speed sensor
DKS : Damping and anti-jackknife system
DR : Pressure regulator
DRM : Pressure control module
DS : Pressure sensor
EBS : Electronic brake system
EBS-SG Electronic brake system - ECU
ECAM : Electronically controlled air management
ECAS : Electronically controlled air suspension
ECU : Electronic control unit
EDC : Electronic diesel control
EFR : Electronic shock absorber control (ESAC)
EHAB : Electro-hydraulic shut-off device
ELAB : Electrical shut-off device
EOL : End-of-line
EPB : Electro-pneumatic brake
FBA : Parking brake system
FNL : Forward-control vehicle, trailing axle, air suspension (semi-pneumatic suspension)
FNLL : Forward-control vehicle, trailing axle, air suspension (full air suspension)
Fz : Vehicle
FR : Long-distance touring coach
FRH : Long-distance high-deck touring coach
FVL : Forward-control vehicle, leading axle, air suspension (semi-pneumatic suspension)
Ger.-D : Silencer
G-Nr. : Device no.
GR : Grau (manufacturer)
HA : Rear axle
HBA : Auxiliary brake system
HY : Hypoid axle
KR : Knorr (manufacturer)
KSW : Special customer request (SA = special equipment)
RA - P 85 1.32 -1
LFA : Air suspension system

LL : Air/air (suspension)
LLL : Air suspension on 3 axles
LT : Air dryer
LP : Air compressor
MA : Centre axle
MG : Centre of articulation point
MV : Solenoid valve
MV-Reg.: Solenoid valve control
NFG : New vehicle generation
NFZ : Commercial vehicle
NLA : Trailing axle
Pa : Polyamide/plastic (pipe)
RA : Repair manual
RFA : Tyre inflation connection
RLV : Relay valve
RREG : European Community Council Directive
RV : Relay valve
SA : Special equipment
SG : Electronic control unit
SI : Service information
SR : Standard coach
SRH : Standard high-deck coach
St : Steel (pipe/tube)
TA : Driven axle
TG-A : Trucknology generation A
L : Intercity bus
V : Overflow valve
VA : Front axle
VLA : Leading axle
VS : Voss (manufacturer)
WA : Maintenance manual
WH : Wabco (manufacturer)
WL : Warning lamp
WLS : Swap-body system
WS : Position sensor
ww. : Alternatively
References to other repair manuals dealing with brake repairs:
P 60 : Device list
P 106 : MERITOR - D - ELSA II disc brakes on vehicle front axle and rear axle
F 13 : HY axles (wheel-brake section for cam/disc brake)
F 14 : AP axles (wheel-brake section for cam /disc brake)
H8 : Non-driven steering front axles (wheel brake section for cam brake)
1.32 - 2 RA -P 85
NEW FEATURES / MODIFICATIONS, TG-A BRAKE SYSTEM
New features / modifications for the brake systems on forward-control vehicles with TG-A cab
The brake system for TG-A vehicles has two important new features and modifications compared to the
previous brake systems. It incorporates 2 electronic systems/system components that were not previously
installed in MAN vehicles:
ECAM
Electronically Controlled Air Management.
EBS
Electronic Brake System.
The most important changes are briefly described below. More precise details of the new units released by
the equipment manufacturers at the time of going to press can be found in section 8.00 - 1 "New units".
1. ECAM Electronically Controlled Air Management, see description on page 1.40 - 1

2. EBS Electronic Brake System (made by Knorr) see description on page 1.50 - 1
3. G 7.xxx Service brake valve with brake power sensor (made by Bosch/Knorr)
4. G 17.xxx Trailer control module (made by Knorr)
5. G 25.xxx Electronically Controlled Air Management (ECAM, made by Haldex) see description on
page 1.40 - 1
6. G 57.xxx Air suspension pressure sensor, see electrical system
7. G 67.xxx Pressure control valves/pressure control modules, 1-channel/2-channel (made by Knorr)
Miscellaneous:
Different diaphragm cylinders on left and right of front axle, for vehicles with MERITOR D-ELSA disc
brakes.
Different combination cylinders on left and right of driven axle, for vehicles with MERITOR D-ELSA disc
brakes.
The pipe installation for the brake and air suspension system on the compressed air side is equipped
with plastic pipes and the new VOSS 232 plug-in connection system. Handling and repair instructions
are included in a separate section of the Repair Manual (section 7.00-1).
RA - P 85 1.33 -1
FUNCTIONAL DESCRIPTION, ELECTRONICALLY CONTROLLED AIR MANAGEMENT (ECAM)
Functional Description (ECAM):

Electronically Controlled Air Management
Heavy Range TG-A
10. 2002
RA - P 85 1.40 - 1
1. General information
1.1 ECAM - use

ECAM is designed for installation in commercial vehicles, buses and coaches with compressed air brakes,
with or without air suspension and/or with other additional pneumatic devices. It is installed between the air
compressor and the air reservoirs. The ECAM
components are located within a single housing.
1.2 ECAM - features
ECAM comprises the following system components, all

of which are integrated in a single housing:
Pressure regulator
Air dryer cartridge
Multi-circuit protection valve
Pressure limiting valves
Safety valves
Regeneration system without separate regeneration
reservoir
Filling connection for filling from an external source
Heating (optional)
Parking brake monitor to ECE R13, A.8, 2.3
CAN bus
ISO 9141, interface
Electronic control unit (ECU)
ECAM controls and monitors the following functions/

states:
Air compressor idling during engine starting
Control of air dryer cartridge regeneration sequence
Control of air reservoir filling sequence
Pressure indicated by on-board display
Air reservoir pressure monitoring by means of pressure sensors
Electronically controlled air management status monitoring
Fault/maintenance information
Air compressor operation under load preferred when vehicle decelerating
1.3 ECAM - advantages
Freely programmable pressure regulator operating range

Controllable regeneration sequence
Individual pressure limitation for each circuit
Pressure indication on display
Start relief during ignition "ON"
No clean-air reservoir
Limp-home characteristics
Compact design
No pressure gauge lines leading to the cab
Fewer pneumatic lines and screw connections
Fewer possible leakage points
1.40 - 2 RA - P 85
1.4 ECAM - meets requirements to:

71/320/EEC - Annex I
2.1.1.1 Load and stress
2.1.1.2 Corrosion
2.2.1.2.6.2 Dual-circuit reservoir
2.2.1.4 Transmission system
2.2.1.4.1 Circuit protectors
2.2.1.5.1 Circuit protectors (auxiliary braking effect in the event of service brake circuit failure)
2.2.1.5.2 Circuit protectors/reservoirs
2.2.1.6 Moving parts
2.2.1.13 Pressure indication on display (warning pressure pressure monitoring red light)
2.2.1.13.1 Audible signal (optional)
2.2.1.13.2 Audible signal - shut-off
2.2.1.16 Brake pressure safeguard/auxiliary consumers
71/320/EEC - Annex V
2.3 Circuit preference
ECE R13 - Annex 8

2.3 Parking brake system locking function
49 StVZO - Annex XXI (German licensing regulations)

2.1 Noise limits
2.2.4 Compressed air noise
1.5 ECAM - general requirements
Pressure regulator shut-off pressure : 8.5 - 12.5 bar

Pressure regulator operating range, el. : 0.6 - 2 bar, adjustable
Safety valve pressure, mech. : adjustable (9 - 15 bar)
Circuit protection pressure, mech. : adjustable (5 - 7.5 bar)
Fording ability : optional
ADR/Hazardous Goods Transport Regs. : optional
1.6 Technical data, general
Thermal application range : -40 C ... +70 C

Max. operating pressure : 14 bar
Burst pressure : > 25 bar
Max. flow rate when idling : 1000 l/min
Max. permitted backpressure when idling : < 1.5 bar
Medium : air
Max. thermal load, not functioning : +80 C/1h
Heat output : 140 W max.
Degree of protection (ECU) : IP 6K9K-DIN 40050T9
Voltage : 16 - 32 VDC
Data bus : CAN
Additional interfaces : ISO 9141
Electrical plug connection : DIN 72 585
Max. permitted air inlet temperature : +65 C
RA - P 85 1.40 - 3
1.7 Technical data for MAN-ECAM, part no. 310 013 ...
Operating pressure = 14 bar max.

Burst pressure = 25 bar
Pressure regulator shut-off pressure = 12.5 bar 0.3 bar (8-13 bar parametric)
Pressure regulator operating range = 2 bar 0.2 bar (0.6-2 bar parametric)
Back-up pressure regulator shut-off pressure = 12.5 bar 0.5 bar (8-12 bar adjustable)
Back-up pressure regulator operating range = 2.5 bar 0.5 bar
Thermal application range = -40 C ... +70 C
Air inlet temperature in ECAM = +65 C max.
ECU component temp. incl. self-heating = +85 C m ax.
Equipment temperature when not functioning = +95 C max. / 18 h or 110 C/1h
Ambient temperature = +70 C max.
Circuit pressure el. circuit (c.) 21, 22, = 12.5 bar max. adjustable (=pressure regulator
shut-off pressure 8-13 bar parametric)
Circuit pressure el. c. 24 = 10 bar, +0.5/-2 bar
Circuit pressure el. c. 23, 23.1 = 8.5 bar +0/-1.3 bar
Circuit pressure el. c. 25 = 12.5 bar (=pressure regulator shut-off pressure
8-13 bar parametric)
Dyn. circuit protection pressure, el. c. 21-24 = 6.5 bar, +1.0 / -0 bar (4.5 - 8 bar parametric)
Safety valve, pressure regulator = 13.5 bar, +1.5 / - 0 bar
Safety valve c. 23 / 23.1 = 8.6 bar, +0.4 / - 0 bar
Mechanical circuit protection valve c. 21-25 = 6.5 bar, +0.8 /-0.6 bar (6-8 bar adjustable)
Connection for filling from external source 11 = 11 bar min. / 12.5 bar max.
(back-up mode)
Connection for filling from external source 11 = 7.5 bar min. / 12.5 bar max.
(electr. mode)
Permitted pressure difference c. 23/23.1 = 0.2 bar 0.2 bar
ECU voltage supply U = 16-32 V DC (36V 1 h)
Current consumption without heating I at 32V = 1.25 A
Current consumption with heating I1 at 32V = 4.3 A 10%
Heating (optional) P = 140 W max.
Electrical connection = DIN 72 585
Pin 1 = Term. 15
2 = K-line
3 = Without heating: not used / with heating: term. 30
4 = Term. 31
5 = CAN-h
6 = CAN-L
7 = Not used
Degree of protection with connector / cable = IP 6K9K
Installation position = Breather downwards
Installation position = Protected from pressure and splash water, not
near the exhaust
Fastening / tightening torque, ECAM = 3xM 12x1.5 - Nm 110
Installation note = In order to allow removal of the air dryer cartridge
there must be a gap of at least 25 mm at the top.
In order to ensure function support, all sides must
have guaranteed free air access for cooling the air
dryer.
1.40 - 4 RA - P 85
2. ECAM functional description - fig. 1

2.1 Engine start and initial filling
2.1.1 Ignition off (fig. 1)
Everything "de-energised"
12 E 12 12 12 12
2 11 11 11 11 19
19
13
9 9 9 10
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Ignition off (pBaus0 (p
Zndung bar)
B = 0 bar)
Fig. 1 Ignition off

Key: The following components are referred to in the functional description
2 Solenoid valve, pressure regulator 4 Pressure regulator, valve
4 Safety valve, pressure regulator 9 Controlled check valve, circuit 21
9 Controlled check valve, circuit 22 9 Controlled check valve, circuit 24
10 Overflow valve, circuit 25 11 Solenoid valve, circuit 21
11 Solenoid valve, circuit 22 11 Solenoid valve, circuit 23
11 Solenoid valve, circuit 24 12 Pressure sensor, pressure regulator
12 Pressure sensor, circuit 21 12 Pressure sensor, circuit 22
12 Pressure sensor, circuit 23 12 Pressure sensor, circuit 24
13 Controlled pressure limiter with pressure protection, circuit 23
19 Solenoid valve, regeneration 19 Regeneration, 2-way valve
P Dryer cartridge L Air compressor
R Check valve E Electronic control unit
A Air distributor
1 Air compressor 3 Breather 11 Filling from external source
21 Circuit 21 (brake circuit, front axle) 22 Circuit 22 (brake circuit, rear axle)
23 Circuit 23 (trailer) 23 1 Circuit 23.1 (spring actuators)
24 Circuit 24 (auxiliary consumers) 25 Circuit 25 (air suspension)
RA - P 85 1.41 - 1
2.1.2 Engine start (fig. 2)

Ignition on
System pressure < 0.5 bar
ECU reset
Engine speed n < n idling
Pressure regulator solenoid valve (item 2) is energised so that starting does not have to take place
whilst the air compressor is operating under load.
Fig. 2 Speed < n idling; air compressor idling
12 E 12 12 12 12
2
11 11 11 11 19
19
13
9 9 9 10
A 11
R
P 21 22 23.1 23 24 25
4
1 3
L
Drehzahl
Speed < n leer
< n idling
1.41 - 2 RA - P 85
2.1.3 Initial filling (fig. 3)
When n n idling the pressure regulator solenoid valve (item 2) is de-energised. The pressure control valve
(item 4) closes and the compressed air flows to the following ECAM devices:
- Air dryer cartridge (item P)
- Check valve (item R)
- Distributor A
- Solenoid valve, circuit 21, 22, 23, 24 (item 11 - 11 )
- Regeneration solenoid valve (item 19)
- Pressure regulator solenoid valve (item 2)
- Controlled check valves, circuit 21, 22, 24 (item 9 - 9)
- Overflow valve, circuit 25 (item 10)
- Controlled pressure limiter with pressure protection, circuit 23 (item 13)
- Regeneration valve (item 19)
Fig. 3 Speed > n idling; initial filling
12 E 12 12 12 12
2 11 11 11 11 19
19
13
9 9 9 10
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
SPEED >n>
Drehzahl idling
n leer
RA - P 85 1.41 - 3
2.1.4 Filling sequence

The initial filling sequence is as follows (note initial filling time): When the solenoid valves (item 11 - 11)
are energised, the circuit valves (item 9 - 9 and 13) are opened one after the other in accordance with the
filling sequence.
Filling of circuit 24 to initial filling pressure, priority 4 (fig. 4)
Filling of circuit 23/23.1 to initial filling pressure, priority 1 (fig. 7)
Filling of circuit 25 after the set opening pressure is reached at the overflow valve, not directly
dependent on the initial filling sequence (fig. 8)
Once the initial filling pressures have been reached in circuits 21-24, all the circuits open and are filled until
the specified shut-off pressure values are reached, i.e.
Circuit 23 8.5 bar max. ( = solenoid valve circuit 23 "off")
Circuit 21/22 12.5 bar
In the case of circuits 21/22, the parameterised deactivation pressure must be greater than the pressure
regulator deactivation pressure so that the solenoid valves of these circuits (item 11, 11) remain
permanently energised when the ignition is "ON" and so that connections 21, 22 are therefore permanently
linked as long as the pressure is greater than the dynamic protection pressure.
Fig. 4 Filling, circuit 24: Solenoid valve 11 is energised. The inlet valve for connection 24 can therefore
open.
12 E 12 12 12 12
11
2 11 11 11 19
19
13
9 9 10
9
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Filling circuit
Fllen 24 24
Kreis
1.41 - 4 RA - P 85
open.
12 E 12 12 12 12
11
2 11 11 11 19
19
13
9 9 10
9
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L Filling
Fllen circuit
Kreis22
22
open.
12 E 12 12 12 12
11
2 11 11 11 19
19
13
9 9 10
9
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Filling
Fllencircuit
Kreis 21
RA - P 85 1.41 - 5
Fig. 7 Filling, circuit 23 / 23.1: Solenoid valve 11 is energised. The inlet valve for connection 23 can
therefore open.
12 E 12 12 12 12
11
2 11 11 11 19
19
13
9 9 9 10
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Fllen
Filling Kreis23
circuit 23
Fig. 8 Filling, circuit 25: Filling of circuit 25 after set opening pressure is reached at overflow valve, not
directly dependent on the initial filling pressures.
12 E 12 12 12 12
11 11
2 11 11 19
19
13
9
9 9 10
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Fllencircuit
Filling Kreis 25 >> 8.5
8,5//<<10
10bar
bar
1.41 - 6 RA - P 85
Once the initial filling pressures have been reached in circuits 21 - 24, all the circuits open and are filled
until the specified shut-off pressure values are reached, i.e.
Circuit 24 10 bar max. ( = solenoid valve circuit 24 "off")
Circuit 21/22 12.5 bar
In the case of circuits 21/22, the parameterised deactivation pressure must be greater than the pressure
regulator deactivation pressure so that the solenoid valves of these circuits (item 11, 11') remain
permanently energised when the ignition is "on" and so that connections 21, 22 are therefore permanently
linked as long as the pressure is greater than the dynamic protection pressure.
2.2 Pressure limiting, circuit 23 and circuit 24

In accordance with the specified shut-off pressure, measured by means of pressure sensor - circuit 23
(item 12'''), solenoid valve circuit 23 (item 11'') is de-energised so that there is no further pressure increase
at connection 23.
In the event of depressurisation after the pressure has fallen below the activation pressure, measured by
the circuit 23 pressure sensor (item 12''') the circuit 23 solenoid valve (item 11 '') is energised until the
deactivation pressure has been reached again.
The same procedure applies in the case of circuit 24 pressure limiting.
2.3 Pressure control
2.3.1 Pressure regulator shut-off

Once the parameterised pressure regulator deactivation pressure measured by the pressure regulator
pressure sensor (12) has been reached, the pressure regulator solenoid valve (item 2) is energised so
that the pressure regulator valve (item 4) is opened and the air compressor (item L) releases air into the
open via connection (3) during idling.
12 E 12 12 12 12
2 11 11 19
11 11
19
13
9
9 9 10
A 11
R
P 21 22 23.1 23 24 25
4
1 3
L
Regeneration
Regeneration
Fig. 9 Shut-off pressure reached. Regeneration
RA - P 85 1.41 - 7
2.3.2 Operating range, pressure regulator activation
Once the parameterised pressure regulator activation pressure measured by the pressure regulator
pressure sensor (item 12) has been reached, the pressure regulator solenoid valve (item 2) is de-
energised so that the pressure regulator valve (item 4) closes. The compressed air compressed by the air
compressor (item L) therefore reaches the air distributor (item A) and other consumers again via the dryer
cartridge (item P).
2.4. Regeneration (fig. 9 and 10)
Fig. 10 End of regeneration
12 E 12 12 12 12
2 11 11
11 11 19
19
13
9
9 9 10
A 11
R
P 21 22 23.1 23 24 25
4
1 3
L Idling
Leerlauf
2.4.1 Regeneration if pressure regulator deactivation pressure is reached

As long as the air compressor is idling, the regeneration solenoid valve (item 19) can be energised in order
to regenerate the dryer cartridge P via the open regeneration valve (item 19'). A corresponding algorithm
for this has been implemented in the electronic control unit (ECU, item E).
2.4.2 Regeneration if pressure regulator deactivation pressure is not reached

In order to allow air dryer cartridge regeneration if more air is required but the pressure regulator
deactivation pressure is not reached, forced regeneration takes place after the specified delivery quantity
has been reached until a specified pressure is reached. Once the specified delivery quantity has been
reached, the pressure regulator solenoid valve (item 2) and the regeneration solenoid valve (item 19) are
energised until either the calculated regeneration air quantity has flowed through the dryer cartridge (item
P) (also see 2.1.8.1) or the specified pressure regulator activation pressure has been reached. If this is the
case, the pressure regulator solenoid valve is de-energised and air compressor operation under load is re-
triggered.
If the calculated quantity of regeneration air does not flow through dryer cartridge P due to the specified
pressure not being reached, the remaining quantity is added during subsequent regeneration. However, the
outstanding regeneration quantity is cancelled when the ignition is switched off. During initial filling,
regeneration is suppressed until the deactivation pressure is reached if the pressure in all circuits was less
than 0.5 bar.
1.41 - 8 RA - P 85
2.5 EBS - brake activation
2.5.1 When VF < 10 km/h
If the pressure falls below the dynamic protection pressure, the assigned solenoid valves of circuits 21, 22
and 23 (item 11, 11', 11'') are energised for the duration of EBS brake activation so that the pressure in
circuits 21/22/23 can be adjusted without a fault being stored in the ECU.
Once EBS brake activation has ended, each assigned solenoid valve is energised cyclically until the
dynamic protection pressure is reached. This means that refilling can take place, even in the event of a low
air compressor delivery rate.
If the pressure in the pressure regulator circuit is < the circuit pressure, cyclic excitation of the affected
solenoid valve is suppressed.
2.5.2 When VF > 10 km/h
If the pressure falls below the dynamic protection pressure, the assigned solenoid valves of circuits 21, 22
and 23 (item 11, 11', 11'') are energised for the duration of EBS brake activation so that the pressure in
circuits 21/22/23 can be adjusted. In contrast to 2.1.9.1, a fault is stored in the ECU when VF > 10 km/h.
Once EBS brake activation has ended, the assigned solenoid valves are energised cyclically until the
dynamic protection pressure is reached. This means that refilling can subsequently take place.
If the pressure in the pressure regulator circuit is the circuit pressure, cyclic excitation of the affected
solenoid valve is suppressed.
2.6 Circuit defect
2.6.1 Leakage
If leakage occurs in one of the circuits 21-24, the affected solenoid valve (item 11 - 11 ''') 'is energised after
the pressure falls below the activation pressure measured by the corresponding pressure sensors (item
12', 12'', 12''', 12'''')' so that the pressure level can remain higher than the dynamic protection pressure.
If the pressure falls below the dynamic protection pressure, the solenoid valve in the affected circuit is
energised cyclically until the dynamic protection pressure has been exceeded and, subsequently,
permanent energisation results in normal filling.
If the pressure in the pressure regulator circuit is the circuit pressure, cyclic excitation of the affected
solenoid valve is suppressed. If the pressure remains below the dynamic protection pressure for longer
than the recovery time (parameter), a fault is recorded in the ECU.
RA - P 85 1.41 - 9
2.6.2 Line break
In the event of a break in one of the lines, all circuits are lowered and then blocked until the dynamic
protection pressure is reached.
When the pressure in the circuit affected by the line break falls below the minimum pressure, in spite of
cyclic energisation of the assigned solenoid valve, the assigned solenoid valve is energised in cycles
throughout the duration of the parameterised recovery time.
If the minimum pressure is still not reached after the recovery time has elapsed, cyclic energisation of the
solenoid valve in the affected circuit is stopped and the circuit is disconnected to prevent further filling
attempts.
In the event of a break in the line for circuit 25, all other circuits are lowered to the opening pressure of the
mechanical circuit protection valve for circuit 25.
Fig. 11 Circuit failure, circuit 21
12 E 12 12 12 12
11 11 11
2 11 19
19
13
9
9 9 10
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Kreisausfall
Circuit failure K21,
K21,nn
> >n nleer, p <p8,5
idling, barbar
< 8.5
1.41 - 10 RA - P 85
12 E 12 12 12 12
11 11 11
2 11 19
19
13
9
9 9 10
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Kreisausfall
K22,n n>>nnleer, p <p8,5
idling, bar
< 8.5 bar
12 E 12 12 12 12
11 11 11
2 11 19
19
13
9 9 9 10
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Kreisausfall K23,n n>>nnleer,
idling,
p <p8,5
< 8.5
barbar
RA - P 85 1.41 - 11
12 E 12 12 12 12
11 11 11
2 11 19
19
13
9
9 9 10
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Kreisausfall
K24,n n> >nnleer, p <p8,5
idling, bar
< 8.5 bar
12 E 12 12 12 12
11 11 11 11
2 19
19
13
10
9 9 9
A 11
R
4
P 21 22 23.1 23 24 25
4
1 3
L
Kreisausfall
K25,n n> >nnleer, p <p8,5
idling, bar
< 8.5 bar
1.41 - 12 RA - P 85
2.6.3 Refilling of a deactivated circuit
If the pressure in a circuit falls below the minimum pressure, this circuit is only re-included in the filling
process through cyclic energisation of the assigned solenoid valve once the fault has been rectified and the
minimum pressure has been exceeded by means of the assigned controlled relay valve (item 9 - 9) or the
controlled pressure limiter with pressure protection (item 13) the next time the air compressor is operated
under load. If the dynamic protection pressure is then reached, the affected circuit is subsequently included
in the control sequence and filled without restrictions.
RA - P 85 1.41 - 13
3. ECAM with back-up pressure regulator

An older version of ECAM was also equipped with a mechanical back-up pressure regulator.
Additional components included:
6 Back-up pressure regulator 6 Pressure retaining valve, backup
14 Control circuit, electrical for item 9 14 Control circuit, electrical for item 9
14 Control circuit, electrical for item 9 15 Control circuit, back-up for item 4
16 Check valve 16 Check valve
17 Control circuit for deactivating the back-up pressure regulator
18 Shuttle valve
Here the pressure was controlled mechanically even if the ECAM was de-energised or if the ECU failed;
however, this could not be used in practice as no pressure information was sent to the driver's display in
this state, meaning that the vehicle could no longer be operated.
Fig. 16 Ignition off pB = 0 bar - back-up
12 E 12 12 12 12
18
2 11 11 11 11 19
17
19
14 14 13 14
6
6
9 9 9 10
16
A 11
R 15
4
P 21 22 23.1 23 24 25
4
1 3
L
Ignition
Zndungoff (p
aus
B 0 bar)
(pB = 0 bar)
RA - P 85 1.42 - 1
4. Software parameters and ECU function sequences
4.1 Ignition "on" - resetting
When the ignition is switched "on", hardware resetting initially takes place. All solenoid valves are inactive
during this time.
4.2 Ignition "on"
Once the ignition has been switched on and resetting is complete, the pressure regulator solenoid valve is
energised automatically so that the air compressor is always relieved of load for starting.
4.2.1
ECAM control is effective at pressures above the dynamic protection pressure, i.e. the individual circuits
are pneumatically active.
4.2.2
Control is not effective at pressures below the dynamic protection pressure, i.e. the circuits are inactive.
4.3 Starting
After the engine has reached idling speed, the pressure regulator solenoid valve is de-energised so that the
air compressor can be operated under load.
4.3.1
At VF < 10 km/h, circuits 21/22/23 are opened and no faults are recorded for the duration of EBS brake
actuation if the parameterised dynamic protection pressure is not reached by the time the circuit protection
valves close automatically.
4.3.2
At VF > 10 km/h and when the pressure is below the parameterised dynamic protection pressure, faults are
always recorded once the recovery time has been exceeded.
4.4 Starting without CAN engine speed message
If there is no CAN "engine speed" message", e.g. in the event of a fault in the sensor concerned, a pseudo
engine speed is parameterised, the value of which is used in the regeneration algorithm to determine the
regeneration air quantity.
For starting, this means that, as a result of the deactivation of the pressure regulator solenoid valve, the air
compressor pressure line is pressurised and the engine has to be started with the air compressor against
this pressure.
4.5 Initial fill priority (see ECE-R13 -VIII - parking brake system)
The initial fill sequence is defined for the individual consumer circuits 21 - 24. Fill sequence:
circuit 24 - circuit 22 - circuit 21 - circuit 23.
4.6 Initial fill pressure
When a compressed air system is filled for the first time, each of the circuits 21 - 24 is filled to its
parameterised initial fill pressure in accordance with its initial fill priority.
RA - P 85 1.43 - 1
4.7 Initial fill time (see 71/320/EEC-IV-2.1 to 2.6)
To enable monitoring of the initial fill in circuits 21 - 24, each circuit is assigned a parameterised initial fill
time which is only started once idling speed has been reached. The parameterised initial fill pressure must
be reached in the individual circuits before this time elapses. If the initial fill pressure is not reached within
this time, filling does not initially continue in the circuit concerned and only recommences once the other
intact circuits have been filled (if less than the minimum pressure for the duration of the recovery time, if
dynamic protection pressure is as per 4.9).
4.8 Warning pressure indicator (immobiliser enable pressure)
In order to ensure a circuit pressure for achieving the auxiliary braking effect, each of the circuits 21 - 24 is
assigned a parameterised warning pressure:
The existing error message only becomes inactive once the parameterised value has been reached in the
last filled circuit.
The error message is reactivated if the level in one of the circuits falls below the value, meaning that the
statutory requirements stipulated in 71 / 320 EEC - Annex 1, 2.2.1.13 are fulfilled at the same time.
4.9 Dynamic protection pressure
In order to protect the pressure in circuits 21 - 24, each circuit is assigned a parameterisable protection
pressure value (6.5 bar).
The assigned solenoid valve is de-energised once the value falls below the parameterised value.
However, this does not apply in the case of an initial fill sequence.
If the pressure is less than the dynamic protection pressure, the affected solenoid valve is energised in
cycles for approx. 50 ms in an attempt to raise the circuit pressure concerned back above the
parameterised dynamic protection pressure value.
If this proves successful, the circuit is considered available without restriction once more. If the pressure in
the pressure regulator circuit is less than 7 bar (pdyn. + 0.5 bar), cyclic excitation of the solenoid valve
concerned is suppressed.
4.10 Minimum pressure
If the pressure in one of the circuits 21 - 24 falls below a parameterised minimum pressure individually
assigned to each circuit, the solenoid valve in the affected circuit is energised in one-second cycles in an
attempt to raise this circuit pressure back above the parameterised minimum pressure.
4.11 Recovery time
In order to reach the minimum pressure as per section 4.10 and to prevent permanent cycling of the
assigned solenoid valve if a circuit fails, each of the circuits 21 - 24 has been assigned a parameterisable
recovery time (typically 1 second).
4.12 Activation pressure
Pressure regulator circuit and consumer circuit 21 - 24 trigger filling / air compressor operation under load
by means of a parameterisable activation value (= nominal activation pressure) after the pressure has
fallen below the parameterised activation pressure.
4.13 Deactivation pressure
Pressure regulator circuit and consumer circuit 21 - 24 limit the max. possible circuit pressure at which the
assigned solenoid valve is deenergised / energised in the pressure regulator circuit by means of a specific
parameterisable deactivation pressure (= nominal deactivation pressure).
This value should be lower than the maximum pressure.
4.14 Maximum pressure
Each circuit (pressure regulator, 21-24) is assigned a parameter for the maximum pressure. If the pressure
exceeds the parameterised pressure value, the affected circuit is deactivated and the ECU detects a
plausibility error.
1.43 - 2 RA - P 85
4.15 Idling speed
If the speed sent by the CAN bus is greater than the parameterised value, it is assumed that the engine is
running and the air compressor is delivering so that the pressure regulator solenoid valve can be de-
energised. This means that the engine is always started when the air compressor pressure line is
depressurised.
4.16 Regeneration
4.16.1 Regeneration at pressure regulator deactivation pressure
A regeneration algorithm based on delivery quantity and regeneration time with temperature adjustment
has been created for the purpose of regenerating the air dryer cartridge.
In this instance, regeneration always takes place once the pressure regulator deactivation pressure has
been reached.
4.16.2 Regeneration if pressure regulator deactivation pressure is not reached
A delivery quantity-specific forced regeneration algorithm has been implemented for delivery quantities
which do not lead to the pressure regulator deactivation pressure being reached, even after longer periods
of delivery, due to excessive air requirements. This algorithm allows regeneration up to a parameterisable
pressure regulator deactivation pressure.
This regeneration begins when the parameterised regeneration activation pressure is exceeded if a
parameterised delivery quantity has been exceeded.
4.17 Heating
The optional ECAM heater is controlled based on the relevant outside temperature which is sent to the
ECAM in the form of a CAN message.
4.18 ECONO mode
ECONO mode allows air compressor operation under load when the vehicle is decelerating, even at
pressures above the parameterised pressure regulator activation pressure. For this to happen, the ECAM
receives a CAN message stating that only a minimum input torque is present. When the relevant pressure
regulator circuit pressure falls below the deactivation value by a certain parameterisable value, air
compressor operation under load is triggered.
Here, it must be noted that ECONO mode is activated after approx. 5 seconds.
4.19 Pseudo engine speed
If there is no CAN "engine speed" message, the system uses this parameterised value to calculate
regeneration and the start-up characteristics.
4.20 CAN bus
ECAM sends the following information:
Pressure circuit 21 - circuit 24 and pressure regulator circuit

Warning pressure (immobiliser enable pressure)
Status information
Circuit control failure in the form of a DM 1 message (applies to circuit 21 - 24 and pressure regulator
circuit)
RA - P 85 1.43 - 3
ECAM requires the following CAN messages:

Outside temperature
Engine speed
Deceleration mode
EBS activation
Vehicle speed
Date, time
4.21 Diagnostic communication
Diagnostic communication is via:
MAN-cats II (KWP 2000) OFFBOARD

DM4 ONBOARD
4.22 Safety shut-down
If the voltage supply is interrupted and a ROM/RAM error occurs, total ECAM shut-down is triggered.
1.43 - 4 RA - P 85
Annex
Technical data:

Pressure regulator shut-off pressure = 12.5 bar 0.3 bar (8-13 bar parametric)
Pressure regulator operating range = 2 bar 0.2 bar (0.6-2 bar parametric)
Back-up pressure regulator shut-off pressure = 12.5 bar 0.5 bar (8-12 bar adjustable)
Back-up pressure regulator operating range = 2.5 bar 0.5 bar
Equipment temperature when not functioning = +95 C max. / 18 h or 110 C/1h
Circuit pressure el. c. 21, 22, = 12.5 bar max. adjustable (=pressure regulator
shut-off pressure 8-13 bar parametric)
Circuit pressure el. c. 24 = 10 bar, +0.5 / -2 bar
Circuit pressure el. c. 23, 23.1 = 8.5 bar +0/-1.3 bar
Circuit pressure el. c. 25 = 12.5 bar (=pressure regulator shut-off pressure 8-
13 bar parametric)
Dyn. circuit protection pressure, el. c. 21-24 = 6.5 bar, +1.0 / -0 bar (4.5 - 8 bar parametric)
Safety valve, pressure regulator = 13.5 bar, +1.5 / - 0 bar
Safety valve c. 23 / 23.1 = 8.6 bar, +0.4 / - 0 bar
Mechanical circuit protection valve c. 21-25 = 6.5 bar, +0.8 /-0.6bar (6-8 bar adjustable)
Connection for filling from external source 11 = 11 bar min. / 12.5 bar max.
(back-up mode)
Connection for filling from external source 11 = 7.5 bar min. / 12.5 bar max.
(electr. mode)
Permitted pressure difference c. 23/23.1 = 0.2 bar 0.2 bar
ECU voltage supply U = 16-32 V DC (36V 1 h)
Current consumption without heating I at 32V = 1.25 A
Current consumption with heating I1 at 32V = 4.3 A 10%
Pin 1 = Term. 15
2 = K-line
3 = Without heating: not used / with heating: term. 30
4 = Term. 31
5 = CAN-h
6 = CAN-L
7 = Not used
Degree of protection with connector / cable = IP 6K9K
Installation pos. = Protected from pressure and splash water, not
near the exhaust
Fastening / tightening torque, ECAM = 3xM 12x1.5 - Nm 110
have guaranteed free air access for cooling the
air dryer.
RA - P 85 1.43 - 5
FUNCTIONAL DESCRIPTION, EBS - BRAKE SYSTEM
Functional Description
Electronic Brake System (EBS)

Heavy Range TG-A
10. 2002
RA - P 85 1.50 - 1
Advantages of EBS
Increase in brake reliability

MAN did not just meet the statutory requirements when developing EBS. Top priority was given to
increasing reliability and user benefit. As a result, a vehicle with EBS can easily exceed the statutory
requirements.
Several factors contribute to the high level of EBS reliability

Faster brake response on the front and rear axles
Improved ABS function
Optimum tractor/trailer harmonisation every time
Permanent monitoring of brake system components and brake wear on front and rear axles
Integral ASR function ensures optimum vehicle stability and traction, even when starting from rest
Reduction in service costs

The electronically controlled brake system combines a whole host of functions. One of the objectives is
to reduce service costs whilst maintaining maximum brake reliability. This is achieved by minimising the
wheel brake wear, for example.
Pressure control based on wear criteria on the front and rear axle harmonises brake wear. Overall wear
is minimised due to the equal load/wear on each of the wheel brakes. This means that all the brakes
can be serviced and changed at the same time. Downtime costs are reduced significantly.
The vehicle operator makes significant savings. A comparison of the service costs for wheel brakes on
an electronically braked vehicle with those for a state-of-the-art conventionally braked vehicle reveals
that the electronic version costs a lot less.
Tractor and trailer compatibility

Conventional aids often fail to ensure adequate brake harmonisation on the tractor and trailer, especially if
several different tractor/trailer combinations are used.
Poor brake harmonisation, e.g. due to insufficient trailer braking, causes uneven brake wear. The
electronically controlled brake system detects when there is too little or too much braking on the trailer and
automatically adjusts the braking power so that each section of the vehicle brakes its own mass. Making
sure that the brakes operate at the optimum point ensures low brake service costs as well as maximum
safety and comfort, even when towing a trailer.
Extensive diagnosis options

Easy-to-service systems are an absolute must for effective fleet logistics. EBS allows the vehicle operator
to monitor the state of the brake system and the level of wheel brake wear at all times, thus enabling
anticipatory service planning. EBS monitors all the major components as well as correct functioning of the
brake system. The system detects any defects and, during servicing, provides precise indications. Trained
service engineers can precisely diagnose the problem and remedy the fault using the test program
developed for troubleshooting.
RA - P 85 1.50 - 3
1 Electronic Brake System (EBS)

1.1 EBS definition
1.1.1 EBS designation
Designation for the entire system: EBS Electronic Brake System
2.1 Second generation
With the sub-functions: EPB Electro Pneumatic Brake
ABS Anti-lock Brake System
ASR Anti-Spin Regulator
1.1.2 EBS function circuit
EBS is the designation for the system incorporating all the subfunctions.
EPB controls the brake pressure. Without ABS,
this continues until full pressure modulation.
Auxiliary functions influence electronic brake
EBS scope pressure control. This results in variable brake
pressure distribution to the brake cylinders on the
vehicle axles, based on specified criteria.
Adhesion Electronic brake pressure control is backed up by
a pneumatic control system (back-up circuit) which
Braking is automatically activated in the event of an
electrical failure.
ABS controls the brake pressure if the wheels

Driving Slip start to lock and deactivates the auxiliary brake.
ASR controls the brake pressure on driven axles if

the wheels start to spin and/or reduces the engine
power.
ABS and ASR operate in a similar way to previous
brake systems.
1.2 Features
EBS for commercial vehicles
Conventional parking brake system: Mechanically actuated, with pneumatic signal transmission
Service brake system: Electronically controlled by the single-circuit vehicle electrical system, with dual-
circuit pneumatic back-up circuit.
24-volt vehicle electrical system
Reservoir pressure up to 12.5 bar
Brake cylinder pressure up to 10 bar
Pneumatic dual-line brake system with conventional trailer control valve or with trailer control module
7-pole electrical plug connection to DIN ISO 7638 between tractor and trailer
EBS ECU with CAN data transfer controls data transfer via
General CAN: EBS ECU to other systems in the tractor to SAE J1939
Trailer CAN: EBS ECU, tractor/trailer to Draft ISO 11992
Brake CAN: EBS ECU to pressure control modules in tractor and trailer
Single-channel pressure control modules with integral electronic unit
Dual-channel pressure control module with integral electronic unit
Speed sensors and brake wear sensors are connected to the pressure control modules (single-channel
pressure control module, dual-channel pressure control module) mounted near the wheels.
EBS can be extended to include 8 speed sensors and 6 pressure control modules in the tractor
(8S/6C = channel). When initially introduced only 4S/4C systems
ASR function with brake and engine regulator (via general CAN)
Additional function switches (e.g. ASR spin increase)
Automatic load-dependent brake pressure control (ALB) integrated in EPB
RA - P 85 1.51 - 1
EOL-programmable system configuration and pressure curves based on individual optimisation criteria
(even application of all wheel brakes, pressure flow, brake wear, even adhesion, maximum
deceleration)
Brake wear regulation
Diagnosis with MAN-CATS / KWP 2000
Coupling force control
1.3 Tractor/trailer connecting lines
The following connections are required and need to be made when operating EBS generation 2 in order to
ensure commercial vehicle and trailer exchangeability:
Dual-line compressed air brake system to DIN ISO 1728 with compressed air reservoir and brake line
Plug-and-socket for ABS to DIN ISO 7638; however, with full pin assignment, including contacts 6
1
and 7 = 7-strand connecting cable
1.4 Compatibility of different brake systems
Alongside combinations consisting of tractor and trailer with BOSCH EBS generation 2, combinations with
conventional trailers and with trailers to ISO 11992 and ISO 7368 (7-pole) are also possible.
The effect on the trailer depends on the pneumatic and electrical supply as well as the control lines
connected between the tractor and trailer. The matrix lists the considered combinations for:
Tractor with EBS generation 2 and various trailer configurations
Various tractor configurations with trailers incorporating EBS generation 2
EBS generation 2 conforms to Supplement 2 of Modification Series ECE-R13, Paragraph 5.1.3.1.2. The
tractor sends the required information stipulated in ECE-R13 Paragraph 5.1.3.2 (see "Trailer CAN" in the
electrical system manual) to the trailer via the electrical plug connection.
Pneumatic brake system Control to ISO 11992 via

without ABS with ABS and 7-pole connection to ISO 7638
EBS gen. 2 Electrical
Brake lamp 5-pole (with pneumatic brake system
Tractor with EBS supply connection and electric without
to ISO 7638 brake line) pneumatic
brake line
Control to ISO 11992 via 7-pole
connection to ISO 7638 with pneumatic
and electric brake line
1 2 3 4 5
Trailer functions in the case of the above vehicle combinations

1 The trailer is connected to the tractor via the pneumatic dual-line system and is braked in accordance
with its configuration.
2 The trailer is connected to the tractor via the pneumatic dual-line system and is braked in accordance
with its configuration, including ABS via brake lamp supply.
3 The trailer is connected to the tractor via the pneumatic dual-line system and the 5-pole ABS connection
and is braked in accordance with its configuration, including ABS via ISO 7638.
4 The trailer is connected to the tractor via the pneumatic dual-line system and the 7-pole EBS connection
and is braked in accordance with the brake line pneumatic pressure or the trailer CAN setpoint. The
selection is made by the trailer in accordance with the braking directive. All EBS functions can be
activated.
5 The trailer is connected to the tractor using the pneumatic reservoir line and the 7-pole EBS connection.
The tractor sends a code which indicates that the electrical brake signal is a single-circuit signal via the
trailer CAN (ISO 11992). In accordance with the proposed supplement to the braking directive (5.1.3.5
ECE Directive 13), the trailer is braked independently (see 1.4). Driving is not permitted with this
combination.
If EBS is integrated in the trailer and only a 5-strand ABS connecting cable is used between
the tractor and trailer, trailer malfunctions may occur.
1.51 - 2 RA - P 85
FUNCTIONAL DESCRIPTION, EBS BRAKE SYSTEM
2 Operation
The description is in accordance with the diagrams under point 1.3. Functioning of EBS-specific
components is explained under point 3.
2.1 Driving position
The dual-circuit pneumatic back-up brake circuit is ready for operation when the ignition switch is not
actuated ("off" position) and there is sufficient compressed air available (see braking using back-up circuit,
section 2.2.2). All the solenoid valves in the brake system are de-energised and adopt their basic positions
by mechanical means (springs).
The EBS ECU (14) starts operating after the ignition switch is actuated. Providing there are no faults,
EBS is activated when the brake pedal is released. EBS is supplied from the single-circuit vehicle electrical
system. All the solenoid valves in the brake system are de-energised when the brake is not actuated.
2.2 Braking with the service brake system
2.2.1 Electronically controlled braking (EPB)
The service brake valve (10) is actuated. The brake power sensor integrated in the service brake valve
sends an electrical signal to the EBS ECU (14). This is generated into a brake pressure setpoint in line with
EOL specifications. This is sent to the trailer plug connection (15) (trailer CAN). In addition, the desired
pressures dependent on axle load (ALB) generated in the EBS ECU (14) are sent to the pressure control
modules (11, 16) via the brake CAN. These modules automatically control the brake pressure for the
series-connected brake cylinders (5, 6).
The desired pressures sent from the EBS ECU (14) to the pressure control modules (11) are adapted
depending on the axle load. In order to determine the axle load-dependent desired pressures, a value for
the axle load is picked up at the air suspension (8), e.g. by a pressure sensor (12), and the measured value
is sent to the EBS ECU (14).
2.2.2 Braking via back-up circuit

The service brake valve (10) modulates two pneumatic brake pressures in the tractor, irrespective of the
brake power sensor electrical signal. These are sent to the pressure control modules (11) in the tractor.
In the case of electronically controlled braking, the pneumatic brake pressure is held as "back-up" at the
pressure control modules. The service brake valve pneumatic pressures are also applied at the trailer
control valve (2) in the tractor. The trailer control valve (2) outputs a pressure to the brake coupling head
(4). The supply is applied at the coupling head (3).
Braking occurs via the back-up circuit when
The ignition switch is in "off" position
The EBS ECU does not send an electrical setpoint to individual or all pressure control modules
The EBS ECU has shut down individual or all pressure control modules following detection of a fault
The solenoid valves in the pressure control module (11) are not energised when braking occurs via the
back-up circuit. They allow the brake pressure output from the service brake valve (10) and the brake
pressure at the control input of the pressure control module to the relay valve in the pressure control
module. This then proportionally supplies a pressure from the connected supply line into the brake
cylinders (5, 6).
2.3 Anti-lock brake system (ABS)

The speed sensors (9) are connected at pressure control module (11) inputs. The signals are forwarded to
the EBS ECU (14) via the brake CAN. The control unit determines a vehicle reference speed and other
variables (flags, limit values) which are then forwarded to the pressure control modules, again via the CAN
bus (brake).
2.3.1 ABS during EPB (with electrical setpoint)

Each pressure control module (11) reduces the brake pressure in relation to the specified nominal pressure
in its control channel, in accordance with a permitted slip value.
2.3.2 ABS and auxiliary brake

The auxiliary brake relay output at the control unit and the "ABS active" information in the EBC1 message
on CAN J1939 indicate whether ABS is active.
The signals are set:
During service brake operation with ABS
When spin is increased without the service brake being actuated
The auxiliary brake can be shut off with these signals during ABS operation.
RA - P 85 1.52 - 1
2.3.3 Control process for commercial vehicle ABS

Four control strategies are available in EBS generation 2. These take effect depending on the combination
of pressure control module, engine speed sensor and EOL programming:
Individual control (IR)
Modified individual control (IRM)
Select-low control (SL)
Select-smart control (SSM)
Individual control (IR)

The brake pressure in a control channel is individually controlled in accordance with the rotating
characteristics of its sensed wheel. In the event of different coefficients of friction on the left/right of the
road, the adapted but different brake powers create a yawing moment around the vertical axis. In order to
enable control of the vehicle reactions whilst braking, the control process is used predominantly on non-
steering axles.
Modified individual control (IRM)
The brake pressure in two control channels is individually controlled in accordance with the rotating
characteristics of its sensed wheels. However, the maximum possible brake pressure on the non-locking
wheel is limited in relation to the wheel which is already being ABS-controlled. Yawing moments are kept
low without causing any considerable increase in braking distance. Used predominantly on steering
axles (axle load-dependent).
Select-low control (SL)
The brake pressure in one control channel is controlled depending on the rotating characteristics of two
sensed wheels. The brake pressure is adjusted to the sensed wheel which first shows a tendency to lock
(low wheel is selected). The transmissible braking power is not utilised on the wheel running at a high
coefficient of friction. With SL, the influence on vehicle stability is positive, the influence on braking distance
negative. Used on single-channel-controlled axles (e.g. trailing axle) or side-specific SL.
Select-smart control (SSM)
The brake pressure in one control channel is controlled depending on the rotating characteristics of two
sensed wheels. In the event of different coefficients of friction on the sensed wheels, intelligent evaluation
enables a higher brake pressure than in the case of SL. This increases the average braking power. Short
locking phases on the wheel running at low coefficient of friction (low wheel) may occur during phases
involving Select-high (SH) control. Used on single-channel-controlled axles or side-based SSM.
2.4 Anti-spin regulator (ASR)
If both the driven wheels spin when the vehicle starts off and accelerates, the ECU recognises this from the
difference in speed between the driven and non-driven wheels and reduces the engine torque (engine
controller).
If the coefficient of friction on the left is not equal to the coefficient of friction on the right (-split), only the
wheel running at the lower coefficient of friction spins in most cases. The spinning wheel is braked by the
ASR brake controller. The drive torque can now take effect on the wheel running at the higher coefficient of
friction. In this way, ASR acts as an automatic differential brake.
ASR can be deactivated when performing tests on a dynamometer. To do this, press the diagnosis button
for longer than 5 seconds.
2.4.1 ASR engine controller
If the driven wheels are spinning evenly, the engine drive torque is reduced until the average rotating speed
of the driven rear axle wheels is slightly higher than that of the non-driven front axle wheels. The EBS ECU
outputs the reduction signal required for the Electronic Diesel Control (EDC) via CAN SAE J1939.
The engine controller can be activated in all road speed ranges. The slip can be varied by activating the
ASR off-road switch.
2.4.1.1 Communication with the engine control unit
Two different communication links are possible:
Pulse width modulation interface (PWM). The protocol is compatible with BOSCH EDC (Electronic
Diesel Control)
CAN interface to SAE J1939
1.52 - 2 RA - P 85
2.4.1.2 Off-road ASR

Under certain off-road driving conditions, the spin can be varied by activating the ASR off-road switch.
Activation of this special state is indicated to the driver by the INA light on the dashboard (permanently lit or
flashing, depending on EOL configuration), and the information "ABS off-road switch active" is set in the
EBC1 message from CAN J1939.
2.4.1.3 Automatic tyre compensation

The system includes an automatic tyre compensation feature. Following a wheel change, it may be that the
ASR engine regulator is activated before tyre compensation is complete.
This can be cancelled by pressing the ASR off-road switch. After a few minutes of driving without braking
on a straight road, the adaptation is complete and ASR off-road can be switched off again.
2.4.2 ASR brake controller

When one wheel starts to spin, the spinning wheel is braked gradually and checked by pressure and speed
sensors. The braking effect reduces the speed of the spinning wheel whilst the speed of the driven wheel
increases as a result of the drive torque. The speeds of the driven wheels are thus synchronised.
The brake controller is not activated at speeds above 40 km/h. However, if it is already active at low road
speeds during acceleration, an appropriate control sequence allows it to remain activated until the next
gear change, even at speeds above 40 km/h. The EBS ECU does not determine the thermal load on the
wheel brakes due to the ASR brake controller. Possible overload during prolonged ASR operation should
be avoided by starting off in an appropriate manner.
If the supply pressure is too low in one of the brake circuits, the ASR brake controller is shut off after one
second. This is why the EBS ECU reads in the voltage potential of the red warning light or the supply
pressure information via CAN J1939.
2.5 Brake wear indication and control
2.5.1 System configuration

Up to 2 brake wear sensors can be connected per pressure control channel (see electrical system manual
for brake wear sensor details). EOL programming (see EOL parameters in electrical system manual) can
be used to individually determine whether each sensor participates in brake wear control.
If 2 brake wear sensors are connected to one single-channel pressure control module, brake wear sensor
supply pin 4 and ground pin 1 (AGND) must be branched outside of the single-channel pressure control
module.
One brake wear sensor curve is programmed for each pressure control module pair (A-B, C-D or E) so that
sensors from different manufacturers can also be used on the same axle (disc brakes / drum brakes).
2.5.2 Brake wear monitoring / indication

Each brake wear sensor (BVS) is only energised during braking, with the exception of the voltage supplied
for initialisation after the ignition switch is switched "ON". Once braking is complete, the electrical signals
are picked up in the pressure control modules and the data are transferred to the EBS ECU via the brake
CAN for evaluation.
Monitoring BVS BVA Error

light memory
Power supply UBVV not as specified X X X
Output signal UBVS error X X X
Max. wear threshold UBVS exceeded X X
Max. permitted wear difference on same axle exceeded X X
ISO diagnosis (ISO 14230) can also be used to scan the current wear state. The relative residual thickness
is output (100% = brakes as new, 0% = brakes worn out)
RA - P 85 1.52 - 3
EOL parameters: Brake wear sensor connected (bit 2 and 3)

Brake wear sensor as switch (bit 3)
Brake wear sensor error zones
Brake wear sensor curves
Brake worn out limit value
Max. permitted wear difference on same axle limit value
2.5.3 Brake wear control

The brake wear control system calculates corrective brake pressure values for each axle based on a
requirement to keep the sum of brake pressures constant in order to ensure harmonisation of brake wear
and an increase in brake lifetime. There is no wheel-by-wheel control.
Based on the brake wear sensor taking part in the control process, the average wear value is calculated for
each axle. These axle wear values (BVaxle) are then also averaged to give the vehicle reference value (Bvref).
The brake pressure correction value (dPaxle) is calculated using the adjustment factor Kadjust:
dPaxle = (BVaxle - Bvref) * Kadjust
The pressure correction value is limited to a maximum permitted pressure value (dPmax).
The adjustment factor Kadjust determines, on the one hand, the conversion of a wear differential (%) into a
pressure value (bar) and, on the other hand, the maximum limit wear as a function of the selected
maximum pressure value (dPmax) based on the following formula: (BVaxle - Bvref) max = dPmax / Kadjust
Provided that the vehicle reference speed is over 10 km/h and there are no brake wear control faults, the
pressure correction value is added to the interpolated load-dependent brake curve of the respective
pressure control module. Addition applies in the case of value pairs 3 and 4. There is no addition in the
case of axles that are not part of the control process.
EOL parameters: Brake wear sensor takes part in control process (bit 4 and 5)
Maximum pressure intervention value
Pressure intervention adjustment factor
2.5.4 Notes
After changing the brakes, check that the brake wear sensor is properly adjusted and correct if necessary
(basic measuring range position). Adjustment as????
Do the brake pad lining plate and brake wear sensor have to be moved back in order to fit new brake
pads/linings?
Are the pressure plate and brake shoe in the starting position?
Is a different class of brake pad/lining thickness (reworked brake disc, brake drum) being used?
Has the brake wear sensor been adjusted to suit the new conditions?
Check to ensure that the brake pads/linings adjust correctly and that the potentiometer is in perfect working
order during the brake safety inspection and after fitting new brake pads/linings.
2.6 Coupling force control

Refer to the electrical system manual for details of coupling force control.
2.7 EBS functional data

General component operating values are included on the quotation drawings. Details regarding EBS
installation are included in the electrical system manual.
2.7.1 Pneumatic pressures
2.7.1.1 Reservoir pressure

Reservoir pressure 12.5 bar
1.52 - 4 RA - P 85
2.7.1.2 Brake cylinder pressure

Limit the EBS-controlled pressure for the pressure control module output to 10 bar or less by limiting the
reservoir pressure or by means of EOL programming
If the available reservoir pressure is not sufficient for setting the required brake cylinder pressure, the
automatic system switches to a different clock pulse (= high sequence protection)
2.7.2 Operating voltages, currents
2.7.2.1 EBS
Vehicle voltage 24 V =
Switching the ignition ON necessitates a sudden change from UZ = 0 V to a sufficient voltage UZ = UB,
otherwise EBS will not be activated. The activated EBS will be subsequently switched to "standby
mode" or deactivated completely in the event of undervoltage or overvoltage, as shown by the figure
below
If the ignition is switched on whilst the brake pedal is depressed, the EBS remains in back-up mode until
the brake pedal is released
The ECU and pressure control module are protected against fluctuations and failures in the voltage
supply by means of hardware and software filters. The supply voltage is monitored by the ECU and
pressure control module. In the event of voltage interrupts > 1 ms, the ECU and affected pressure
control module switch themselves off
Operating states:
Mode Description Red warning light

Off The EBS is de-energised. Braking is by means of the pneumatic ON
back-up circuit. ALB, ABS and ASR are not available (neither via
EBS ECU nor via engine ECU)
Standby EBS ECU and pressure control module are energised. All sensor ON
signals are processed. The solenoid valves remain in their
mechanically defined positions; they are not activated electrically.
Ready The EBS is controlled by the brake power sensor. OFF
Defect The EBS has suffered damage or a failure. Braking is by means of the Depends on the
pneumatic back-up circuit. damaged parts
RA - P 85 1.52 - 5
3 Description of EBS-specific components
3.1 Service brake valve with brake power sensor
3.1.1 Further references

see electrical system manual
3.1.2 Design
An electrical brake power sensor is installed
upstream of the dual-circuit pneumatic service brake
valve/integrated in the service brake valve. A tappet
is used for actuation in each case. The tappet
actuates the brake power sensor and, by means of
the usual springs, a reaction piston and valve
assembly for applying the pneumatic pressure.
A single electrical circuit supplies the voltage for the
brake power sensor. Two potentiometer sensors are
actuated.
The service brake valve is designed for mounting on
the cab.
3.1.3 Function
The brake power sensor is electrically connected to
the EBS ECU in the tractor. Signals SM1 and SM2
run in opposite directions. The EBS ECU uses the
signals SM1 and SM2 to determine setpoints for the
trailer and for the pressure control modules in the
tractor.
EOL programming is used to harmonise the
electrical and pneumatic circuit after the service
brake valve has been installed in the vehicle (see
electrical system manual).
3.1.4 Monitoring
The sum of the sensor voltages (SM1, SM2) is Key:
monitored in the EBS ECU. A signal line short-circuit
is also detected during braking, due to uneven Service brake valve (A)
protective resistances. 3 Air out
11 Energy inflow, circuit 1
12 Energy inflow, circuit 2
21 Energy outflow circuit 1
22 Energy outflow circuit 2
Brake power sensor (B)
1 Ground 3 Pressure setpoint 1
2 Pressure setpoint 2 4 Voltage supply
RA - P 85 1.53 - 1
3.2 1-channel pressure control module

3.2.1 References
3.2.2 Design
Key:
A ABS sensor, front axle, right (B120) C CAN databus and voltage
B Sensor, brake pad, 1st axle, right (B332) or supply
sensor, brake pad, 1st axle, left (B333) 1 Ground
1 Ground 2 Voltage supply
2 Not used 3 CAN HIGH
3 Sensor 4 CAN LOW
4 Voltage supply D ABS sensor, front axle, left (B119)
1 Energy inflow (reservoir) 3 Air out

2 Energy outflow (brake cylinder) 4 Back-up circuit
The pressure control module is a single-channel electro-pneumatic adjuster. It consists of a relay valve,
filter, silencer, solenoid valves for the back-up circuit (back-up valve), inlet and outlet valve, pressure
sensor and electronic control unit as well as pneumatic and electrical connections. It is the node for
transmitting the signals of the connected sensors (speed sensor, brake wear sensor) to the EBS ECU via
the brake CAN.
The pressure control module is designed for mounting in the chassis of commercial vehicles with
downwards-pointing silencer.
1.53 - 2 RA - P 85
3.2.3 Function
During each braking operation, the pressure control module energises the brake wear sensor (section 3.6)
and the sensor signal is measured in the pressure control module
The signals the pressure control module receives from the engine speed sensor and brake wear sensor
are forwarded to the EBS ECU via the brake CAN
If no EBS function is active, the pressure sensor measured value is adjusted in line with the current
brake cylinder pressure using a time constant (automatic atmospheric pressure setting). The adjustment
range is limited and may last approx. 1 second when the ignition is switched "ON" after the parking
brake or service brake has been released. This adjustment time must be taken into account in
measurements (see electrical system manual)
The pressure control module executes open or closed-loop control functions in three different states:
Pressure control module is energised and electrical setpoint available or ASR brake regulation
required (normal function):
When the EBS function is requested, the pressure control module commences brake pressure
regulation by closing the back-up valve and activating the inlet valve/outlet valve accordingly
Pressure control module is energised but no electrical setpoint or actual value available (braking with
the back-up circuit):
If the electrical setpoint or actual value is defective, the system switches the pressure control module
to the back-up circuit (back-up valve is not switched and is open). The pneumatic pressure controls
the pressure to the brake cylinders via the relay valve. There is no ALB available. The speed sensor
signals in the pressure control module are processed and communication between the pressure
control module and EBS ECU is maintained
Pressure control module de-energised:
The solenoid valves are in their initial de-energised position as shown on the diagram in section 3.2.2.
The pneumatic service brake valve pressure controls the pressure to the brake cylinders via the
relay valve (braking with the back-up circuit)
3.3 2-channel pressure control module
3.3.1 References
3.3.2 Design
The 2-channel pressure control module is a dual-channel electro-pneumatic adjuster. It consists of relay
valves, filters, silencers, solenoid valves for the back-up circuit (back-up valve), inlet and outlet valves,
pressure sensors and electronic control unit as well as pneumatic and electrical connections.
It is the node for transmitting the signals of the connected sensors to the EBS control unit (via the brake
CAN):
Speed sensors (DF A, DF B, DF C, DF D)
Brake wear sensors (BVS 1, BVS 2, BVS 3, BVS 4)
Axle load sensors (ALB 1, ALB 2)
The 2-channel pressure control module is designed for mounting in the chassis of commercial vehicles with
downwards-pointing silencer.
RA - P 85 1.53 - 3
Key:
A ABS sensor, rear axle, left (B121) E Not used
B Sensor, brake pad, 2nd axle, right (B334) F Sensor, brake pad, 2nd axle, left (B335)
1 Ground 1 Ground
2 Not used 2 Not used
3 Sensor 3 Sensor
4 Voltage supply 4 Voltage supply
C ALB sensor, rear axle (B336) G CAN databus and voltage supply
1 Ground 1 Ground
2 Not used 2 Voltage supply
3 Sensor 3 CAN HIGH
4 Voltage supply 4 CAN LOW
D Not used H ABS sensor, rear axle, right (B122)
1 Energy inflow (supply) 3 Air out

21/22 Energy outflow (brake cylinder) 4 Back-up circuit
3.3.3 Function
The brake wear sensor is energised at the end of each braking operation so that the current status of
the of the sensor signal can be determined
The signals the pressure control module receives from the speed sensor, brake wear sensor and ALB
are forwarded to the EBS ECU via the brake CAN
If no EBS function is active, the pressure sensor measured value is adjusted in line with the current
brake cylinder pressure using a large time constant (automatic atmospheric pressure setting).
Adjustment is limited and may last up to 1 second after the ignition is switched ON or the service
brake is released. This adjustment time must be taken into account in measurements (see electrical
system manual)
The pressure control module executes open or closed-loop control functions in three different states:
Pressure control module ECU is energised and electrical setpoint available or ASR brake regulation
required (normal function):
When the EBS function is requested, the pressure control module commences brake pressure
regulation by closing the BV and activating the inlet valve/outlet valve accordingly
1.53 - 4 RA - P 85
Pressure control module ECU is energised but no electrical setpoint or actual value available
(braking with the back-up circuit):
If the electrical setpoint or actual value is defective, the system switches the pressure control module
to the back-up circuit (BV is not switched). The pneumatic pressure controls the pressure to the
brake cylinders via the relay valve. There is no ALB or wear control. The signals in the pressure
control module are processed and communication between the pressure control module and EBS
ECU is maintained
Pressure control module ECU de-energised:
The solenoid valves are in their initial de-energised position as shown on the diagram in 3.2.2.
The pneumatic service brake valve pressure controls the pressure to the brake cylinders via the
relay valve (braking with the back-up circuit)
Key:
A ABS sensor, rear axle, left (B121) E Not used
B Sensor, brake pad, 2nd axle, right (B334) F Sensor, brake pad, 2nd axle, left (B335)
1 Ground 1 Ground
2 Not used 2 Not used
3 Sensor 3 Sensor
4 Voltage supply 4 Voltage supply
C ALB sensor, rear axle (B336) G CAN databus and voltage supply
1 Ground 1 Ground
2 Not used 2 Voltage supply
3 Sensor 3 CAN HIGH
4 Voltage supply 4 CAN LOW
D Not used H ABS sensor, rear axle, right (B122)
1 Energy inflow (reservoir) 3 Air out

21/22 Energy outflow (brake cylinder) 4 Back-up circuit
RA - P 85 1.53 - 5
3.4 Trailer control module

3.4.2 Design
The trailer control module essentially consists of 2

relay valves for the service brake, one relay valve for
the parking brake, one throttle valve, electromagnetic
valves (input, output, back-up), a pressure sensor
like in the 1-channel pressure control module and an
integrated control unit.
The main function of the trailer control module is

controlling the brake pressure on the trailer control
line (connection 22) and the coupling force between
the tractor and trailer. The parking brake and the
break-away function work in the conventional
manner.
The trailer control module has one electrical and six

pneumatic connections. The electrical connection
contains the energy supply and the CAN connection
to the EBS control unit.
3.4.3 Function
The pressure setpoint in the central control unit is Key:

transmitted to the control unit inside the trailer control 3 Air out
module via CAN. The trailer control module control 11 Energy inflow (reservoir)
unit modifies this setpoint using the coupling force 21 Reservoir line, trailer
control algorithm, i.e. it converts the electrical signal 22 Control line, trailer
into a pneumatic signal in control cell 41 using 41 Service brake circuit, front axle
electromagnetic input and output valves and a 42 Service brake circuit, rear axle
pressure sensor. 43 Parking brake circuit
This is transmitted to the coupling head on the trailer
control line (connection 22) via the relay valve.
Control cell 41 blocks pneumatic input signal 42 by means of a back-up solenoid valve which is activated
for electric braking. When the back-up function is active, it opens and forwards the operating pressure 22 to
the brake coupling head 22 via the control cell.
The service brake pressure 21 is present at connection 41 of the trailer control valve and operates a
separate relay valve. This relay valve has an application pressure of 3 bar, whilst the output pressure is
restricted to a maximum EBS pressure reduced by 4 bar. If the EBS and service brake pressure 22 fail, the
pneumatic curve is switched over so that, when there is 7 bar at connection 21, there is also 7 bar at the
trailer control line 22. A reduction in the reservoir pressure does not change the circuit 41 pressure back-
up.
Pneumatic connection 43 is pressurised during driving, meaning that the brake cylinders in the trailer are
not braked. Activation of the parking brake pressurises the trailer control line and thus brakes the trailer.
If trailer control line 22 becomes torn, the pressure supply for trailer reservoir line 21 is severely restricted
by an automatically closing throttle so as to ensure that the supply pressure falls below 1.5 bar within
2 seconds.
1.53 - 6 RA - P 85
3.5 Axle load sensors

3.5.2 Design
The sensors are electrically connected to the 2-channel pressure control module (see brake function
diagrams in section 2.00)
3.5.2.1 Axles with leaf suspension (position sensor)

The sensor is fastened on the vehicle body. The vertical motion of the axle is transferred to the lever of the
actuating shaft. There is a voltage divider in the sensor.
Refer to the notes in the electrical system manual etc. for details regarding installation and the compression
effect.
3.5.2.2 Axles with air suspension (pressure sensor)

The pressure sensor is fastened on the vehicle body. It contains a pressure-sensitive measuring element
and a booster circuit. The pneumatic connection is connected with an air bellows (or corresponding line).
The maximum pressure specified on the pressure sensor indicator applies to all operating states.
3.5.3 Function
Conversion of the physical variable (position, pressure) into a voltage.
The sensors are supplied with a voltage U = 5 V by the 2-channel pressure control module. They supply
the analogue compression or pressure-dependent voltage Ua. Load-dependent adjustment is assigned to
this ALB sensor value Q by means of EOL programming. This assignment allows axle load-dependent
pressure interpolation for e.g. ALB or yawing moment limiting by IRM in the case of ABS (section 2.3.3).
3.5.4 Monitoring
Monitoring of the voltage equation:
Ua
Permitted operating range: 0.08 0.88
U
RA - P 85 1.53 - 7
4 Instructions
An electronic monitoring system checks the functional availability of all the major EBS electrical
components both before and during driving. The red and yellow lights come on when the key is in the "ON"
2
position on the steering lock. The lights go out after 3 seconds . However, dynamic testing of the speed
sensors is not completed until 4 seconds after the road speed exceeds 10 km/h.
If the red and yellow lights do not go out, this indicates that the EPB and/or ABS/ASR has been shut down
2
due to a fault . If the red or yellow light comes on whilst the vehicle is being driven, this indicates that a fault
has been detected. Electrical functions are shut down if one of the lights comes on. The braking
characteristics are altered as a result. Have the EBS checked at an authorised Service workshop
2
immediately in order to prevent further faults with unpredictable effects. Drive to the nearest Service
workshop at reduced speed and exercise due caution.
We also recommend regular servicing of the brake system in order to check those functions which cannot
be monitored by the electronic monitoring system in its current state of development.
Following repairs, a functional test must be performed on the entire brake system, including the
pneumatic back-up circuit. This test must include an effective check to ensure that the connected
pneumatic and electrical lines are assigned to the correct valves, sensors and control unit.
Work on the EBS may only be performed by authorised personnel.
It is the driver's job to monitor all the warning and information lights. If one of the lights does not come on
immediately after the ignition is switched ON, this indicates that the light is defective and needs replacing
without delay.
4.1 Operating notes

EBS is not able to compensate for an insufficient safety distance between your vehicle and the vehicle in
front or excessive cornering speed, nor does it ensure unrestricted winterisation (snow chains).
2
Provided that no other equipment is triggering/activating the red light (e.g. reservoir pressure)
RA - P 85 1.54 - 1
EBS COMPONENT DESCRIPTION
5.1 EBS control unit (device no. A402)
The EBS control unit centrally controls the entire EBS system and communicates with other
systems such as Electronic Diesel Control (EDC) or the gearbox ECU.
A402
Electronic control unit design

The housing contains a printed circuit board with a multipoint connector. The control unit electronic system
has integrated circuits, microcontrollers and discrete components.
When voltage is supplied, a filter in the "voltage supply" module protects against electrical faults at
terminal 15 and terminal 30. A supply voltage for the pressure control modules and a voltage of 5 volts for
the sensors are forwarded. The module also supplies a stabilised voltage of 5 volts for internal control unit
operation.
Input circuits are for conditioning the signals for the microcontroller (C) input.
Superimposed spurious signals on the inputs are filtered. Information is transmitted in both directions at the
diagnosis interface, i.e. to the control unit and from the control unit, e.g. to the diagnosis unit (MAN-cats).
The computer (in the control unit) contains two redundant microcontrollers (C) with EEPROM and three
CAN controllers (general CAN, trailer CAN, brake CAN). The microcontrollers evaluate the signals
conditioned by the input circuits and control the output via CAN databus.
Following module supply, each pressure control module is activated successively and given a CAN
address by the microcontroller (C) after the EBS control unit has been activated.
The pressure control modules can be deactivated individually, e.g. when system faults are detected.
CAN interfaces
General CAN: Data exchange with other control units.
Trailer CAN: Data exchange with the trailer.
Brake CAN: Data exchange between the EBS control unit and the pressure control modules in the
tractor/trailer.
The output stages activate peripherals such as the auxiliary brake relay, brake wear indicator, information
display lamp and yellow warning light. The red warning light is activated by a self-conducting output stage.
RA - P 85 1.55 - 1
Diagnosis interface
Diagnosis of the tractor unit is performed via diagnosis connector X200.
The MAN-cats testing system incorporating the necessary test software is connected at this interface.
Errors detected by the control unit can be read out, decoded and displayed. This testing system is also
used to clear the error memory.
Vehicle-specific EOL programming is also performed via the diagnosis interface.
Pin assignment - as seen looking at the control unit
Connector drop-out detection

A switch integrated in the cable harness plug connector (pin X1/15) activates the red warning lamp by
closing contacts X1/12 and X1/18 on the cable harness side as soon as the cable harness is not connected
or drops out due to loosening.
The switch is opened again if the wiring harness is connected to the control unit.
Note: (wiring diagram, section 6)

Connector drop-out detection
Short-circuit spring insulated by control unit cell X1/15 when inserted.
Pin X1/12 and pin X1/18 short-circuit if not inserted.
Connector terminal assignment and description
Connector X1
Pin Line no. Designation

6 74512 Switch, ASR spin threshold increase, control unit, EBS
7 73001 Fuse F162-voltage supply, control unit, EBS
8 73000 Fuse F161-voltage supply, pressure control valves
10 31000 Earthing point, cab, next to central electrical system
12 31000 Earthing point, cab, next to central electrical system
13 73201 Diagnosis, K-line
15 --- Detection, interrupt (connector drop-out detection)
18 --- Red warning indicator, self-conducting
1.55 - 2 RA - P 85
Connector X2

2 73500 Voltage supply, brake power sensor
3 73501 Ground, brake power sensor
4 73503 Pressure setpoint 2 from brake power sensor
7 73502 Pressure setpoint 1 from brake power sensor
Connector X3

2 CAN 112 Ground, pressure control module, 1-channel, left
3 CAN 122 Ground, pressure control module, 1-channel, right
5 CAN 114 CAN_L for pressure control module, 1-channel, left
6 CAN 124 CAN_L for pressure control module, 1-channel, right
8 CAN 113 CAN_H for pressure control module, 1-channel, left
9 CAN 123 CAN_H for pressure control module, 1-channel, right
11 CAN 111 Voltage supply for pressure control module, left
12 CAN 121 Voltage supply for pressure control module, right
Connector X4

1 Green CAN_L, trailer socket ISO 11992
3 White/green CAN_H, trailer socket ISO 11992
4 CAN 132 Ground at pressure control module, 2-channel
6 CAN 141 Ground at trailer control module
7 CAN 134 CAN_L for pressure control module, 2-channel
9 CAN 143 CAN_L for trailer control module
10 CAN 133 CAN_H for pressure control module, 2-channel
12 CAN 144 CAN_H for trailer control module
13 CAN 131 Voltage supply for pressure control module, 2-channel
15 CAN 142 Voltage supply for trailer control module
RA - P 85 1.55 - 3
5.2 Service brake valve with integrated brake power sensor (device no. G7.302/B337)
Design
B337
G7.302
The dual-circuit pneumatic service brake value (G7.302) has an integral electric brake power sensor (B337)
which is used for generating electrical and pneumatic signals for admitting and removing air in the
electronically controlled brake system. A tappet is used for actuation in each case. The tappet actuates the
brake power sensor and, by means of the usual springs, a reaction piston and valve assembly for applying
the pneumatic pressure. A single electrical circuit supplies the voltage for the brake power sensor. Two
potentiometer sensors are actuated.
The brake power sensor is installed at the front end of the cab.
Installation position:
B337
G7.302
1.55 - 4 RA - P 85
5.3 Pressure control module (1-channel) (device no. G67.304/Y262 right and G67.304/Y263 left)
Design
Y262/Y263
G67.304
The pressure control module is a single-channel electro-pneumatic device comprising relay valve, filter,
silencer, solenoid valves for back-up circuit (back-up valve), inlet valve/outlet valve, pressure sensor,
electronic control as well as pneumatic and electrical connections.
It is also the node for transmitting the signals of the connected sensors (speed sensor, brake wear sensor)
to the EBS control unit via the "brake" CAN databus.
The pressure control module is installed on the right and left of the front axle, with the silencer pointing
downwards.
Y262/Y263
G67.304
RA - P 85 1.55 - 5
5.4 Pressure control module (2-channel) (device no. G67.305/Y264)
Design
Y264
G67.305
The pressure control module is a dual-channel electro-pneumatic device comprising relay valve, filter,
silencer, solenoid valves for back-up circuit (back-up valve), inlet valve / outlet valve, pressure sensor,
electronic control as well as pneumatic and electrical connections.
It is also the node for transmitting the signals of the connected sensors to the EBS control unit via the
"brake" CAN data bus:
Speed sensors (1st rear axle and 2nd rear axle)
Brake wear sensors (BVS 1, BVS 2, BVS 3, BVS 4)
Axle load sensors (ALB 1, ALB 2)
The 2-channel pressure control module is installed on the rear axle, with the silencer pointing downwards.
Y264
G67.305
1.55 - 6 RA - P 85
5.5 Trailer control module (device no. G17.301/Y278)
Design
Y278
G17.301
The trailer control module essentially consists of two relay valves for the service brake, one relay valve for
the parking brake, one throttle valve, electromagnetic valves (input, output, back-up), a pressure sensor
like in the 1-channel pressure control module and an integrated control unit.
The main functions of the trailer control module are controlling the brake pressure on the trailer control line
(connection 22) and the coupling force between the tractor and trailer. The parking brake and the break-
away function work in the conventional manner.
The trailer control module has electrical and pneumatic connections. The electrical connections contain the
voltage supply and the connection between the "trailer" CAN databus and the EBS control unit.
G17.301
RA - P 85 1.55 - 7
5.6 ALB sensor, rear axle (device no. B336)
B336
The axle load sensors are electrically connected to the rear axle pressure control module.
If axles with leaf suspension are fitted, the position sensor (see figure) is fastened on the chassis. The
vertical motion of the axle is transferred to the lever which is located on the actuating shaft. There is a
voltage divider in the position sensor.
If axles with air suspension are fitted, the pressure sensors are fastened on the chassis. It contains a
pressure-sensitive measuring element and a booster circuit. The pneumatic connection is connected to a
compressed air line which leads to the air bellows.
B336
1.55 - 8 RA - P 85
5.7 Speed sensors (device no. B119/B120/B121/B122)
The speed sensors are electrically connected to the pressure control module.
The speed sensor is part of the speed sensing system. This consists of a toothed pulse wheel and an
inductive speed sensor. The pulse wheel is mounted in accordance with the familiar ABS requirements.
When the wheel rotates, an alternating voltage is created in the speed sensor, the frequency of which is
proportional to the wheel speed.
RA - P 85 1.55 - 9
5.8 Brake wear sensor (device no. B332/B333/B334/B335)
The brake wear sensors are electrically connected to the pressure control module.
Data are transferred via the "brake" CAN databus.
Electrical circuit
The permanently measuring brake wear sensor is part of the wheel brake.
1.55 - 10 RA - P 85
DESCRIPTION, RESERVOIR AND BRAKE CIRCUITS
Functional description for TG-A vehicles with air dryer
RESERVOIR AND BRAKE CIRCUITS
Circuit 1
Service brake system (21) Consists of reservoir circuit I and brake circuit I for the rear axle and control
of the trailer control valve.
Circuit 2
Service brake system (22) Consists of reservoir circuit II and brake circuit II for the front axle and
control of the trailer control valve.
Circuit 3
Parking brake system (23) Consists of reservoir circuit III for the parking brake system (spring
actuator), the trailer reservoir and control of the trailer control valve.
Circuit 4
Reservoir (24) Consists of reservoir circuit IV (without reservoir tank) and is designed for
the auxiliary brake system and all other auxiliary consumers.
RA-P 85 1.61 - 1
FUNCTIONAL DESCRIPTION
FUNCTIONAL DESCRIPTION, BRAKE SYSTEM
The vehicle is equipped with a multi-circuit compressed air brake system to EC Directives.
The multi-circuit protection valve separates the circuits as follows:

Front axle/rear axle brake circuit (service brake system)
Parking brake circuit (parking brake system)
Auxiliary brake system/auxiliary consumers and air suspension system
The compressed air supply for the service brake system, parking brake system and other brake system
circuits is protected by the multi-circuit protection valve, that is, an overflow valve with limited return flow.
The overflow valve with limited return flow also protects the air suspension reservoir circuit*.
The air suspension system operating pressure is 12.5 bar. The reservoir circuit for the air suspension
system is separated from the reservoir circuits of the service brake system by the branching of line (1)
using an overflow valve with limited return flow (6.4 - 0.3 bar). This ensures that, when the compressed air
system is being filled, at least one service brake circuit is filled up to the protection pressure before the
other systems are filled with compressed air; this means that the vehicle can never be driven away without
an effective brake being available*.
The vehicle is equipped with drum brakes on the front and driven axle or disc brakes on the front axle.
The disc brakes on the front axle are adjusted by the automatic adjuster (friction clutch) in the actuating
mechanism, the brakes on the driven axle (drum brake) by automatic slack adjusters.
The anti-lock brake system (ABS) and anti-spin regulator (ASR) are optional (special equipment).
Compressed air supply
The air supplied by the air compressor flows through the cooling coil, into a surge tank and then into the air
dryer with integrated pressure regulator.
The air dryer is equipped with a changeover cartridge and heater.
The cut-off pressure is 10.0 0.2 bar (without air suspension system)
12.5 0.2 bar (with air suspension system)
The operating range is 1.0 + 0.5 bar (without air suspension system)
1.3 + 0.7 bar (with air suspension system).
The supplied air continues flowing via connection 22 to the clean-air (regeneration) reservoir and via
connection 21 to the branch. From here it flows through an overflow valve with limited return flow, into the
reservoir for the air suspension system and to the multi-circuit protection valve,
In the multi-circuit protection valve, the air is divided between 4 reservoir circuits and directed to the
corresponding reservoirs*.
System leak-tightness
When the air compressor (i.e. engine) is stationary, the pressure in the reservoirs must not fall below the
rated cut-off pressure of the pressure regulator by more than 2% in 10 minutes.
Note:
When changing pressure and warning switches, install the switches vertically with the electrical
connections facing upwards.
"Bar" values are indicated as excess pressure and correspond to the former indications in atmospheres or
2
kp/m .
1.61 - 2 RA-P 85
FUNCTION OF THE BRAKE CIRCUITS
1. When the brake system is operational
Actuation:
1.1 of the service brake (pedal brake)
means the front axle (circuit 2) is braked pneumatically by the diaphragm brake cylinder
as a function of the load,
means the rear axle (circuit 1) is braked pneumatically by means of pressurisation of the
service brake section of the combination brake cylinder automatically and as a
function of the load,
means the trailer is braked by means of pressurisation of the trailer brake line.
1.2 of the parking brake

means the front axle is not braked,
means the rear axle is braked by means of depressurisation of the spring actuator section in
the combination cylinder,
1.3 of the auxiliary brake

means the tractor is braked (decelerated) by means of closure of the exhaust gas throttle and
fuel cut-off via the powertrain,
means the trailer is activated and braked by the auxiliary brake system solenoid valve and
socket (connection 54g) (no longer in the case of trailer to RREG).
RESERVOIR AND BRAKE CIRCUIT FAILURES
If one of the brake circuits fails, one brake circuit always remains available up to the multi-circuit protection
valve closing pressure.
2. Rear axle brake circuit (circuit 1) failure

The reservoir warning light comes on, the dual pressure gauge for reservoir 1 (red pointer) indicates
no reservoir pressure. The pressure in circuit 2 briefly falls to the multi-circuit protection valve closing
pressure and, when the engine is running, rises back to the protection pressure. Circuits 3 (parking
brake system) and 4 maintain full pressure by means of check valves.
When the engine is not running, the still intact circuit 2 falls to closing pressure. Circuits 3 (parking
brake system) and 4 initially maintain the full reservoir pressure still available by means of check
valves; after consumption, these circuits fall to closing pressure and are no longer supplemented.
Actuation:
means the front axle is braked by means of pressurisation of the diaphragm cylinders,
means the rear axle is not braked,

(If the brake line is broken, the pressure differential control valve responds and brakes
the trailer. Pressure loss is indicated on the dual pressure gauge).

socket (connection 54g) (no longer in the case of trailer to RREG).
RA - P 85 1.62 - 1
3. Front axle brake circuit (circuit 2) failure

The warning light comes on, the dual pressure gauge for reservoir 2 (white pointer) indicates no
reservoir pressure. The pressure in circuit 1 briefly falls to the multi-circuit protection valve closing
pressure and, when the engine is running, rises back to the protection pressure. Circuits 3 (parking
brake system) and 4 maintain full pressure by means of check valves. After consumption, these
circuits fall to closing pressure and are no longer supplemented.
When the engine is not running, the still intact circuit 1 falls to closing pressure. Circuits 3 (parking
brake system) and 4 initially maintain the full reservoir pressure still available by means of check
valves. After consumption, these circuits fall to closing pressure and are no longer supplemented.
Actuation:
means the rear axle is braked pneumatically by means of pressurisation of the service brake
section of the combination brake cylinders, automatically and as a function of the load,


socket (connection 54g) (no longer in the case of trailer to RREG)
4. Parking brake circuit (circuit 3) failure

The parking brake warning light comes on. The pointers on the dual pressure gauge indicate reduced
pressure. The pressure in circuits 1, 2 and 4 briefly falls to the multi-circuit protection valve closing
pressure and, when the engine is running, rises back to the protection pressure (6.9 - 0.3 bar).
When the engine is not running, the still intact circuits fall to closing pressure and are not
supplemented.
The rear axle spring brake cylinders move to braking position.
Note:
In vehicles with trailer brake connection only in case of breakage after the check valve before the
parking brake valve.
The trailer is braked as a result of the pressure fall in the reservoir line and remains braked.
Actuation:
means the spring actuator sections in the combination cylinder are depressurised and the rear
axle is braked.
4.2 Pneumatic release of the applied spring actuators

As a result of actuation of the parking brake valve in release position, air flows out of circuit 24 into the
spring actuators and releases the parking brake.
In the event of total compressed air system failure, the spring actuators can be released mechanically,
see Operator's Manual.
1.62 - 2 RA - P 85
5. Auxiliary consumer reservoir (circuit 4) failure

The reservoir warning light comes on. The pointers on the dual pressure gauge indicate reduced
pressure. The pressure in circuits 1, 2 and 4 briefly falls to the multi-circuit protection valve closing
pressure and, when the engine is running, rises back to the protection pressure (6.9 - 0.3 bar).
When the engine is not running, the still intact circuits fall to closing pressure and are not
supplemented.
Actuation:
means the front axle is braked by means of pressurisation of the diaphragm cylinders,
means the rear axle is braked pneumatically by means of pressurisation of the service brake
section of the combination brake cylinders, automatically and as a function of the
load,


socket (connection 54g) (no longer in the case of trailer to RREG)
6. Reservoir (air suspension system) (circuit 5) failure

The overflow valve with limited return flow (6.4 - 0.3 bar) maintains the supply of compressed air to the
brake system*.
After consumption, the pressure in the air bellows falls to 0 bar and is not supplemented.
7. Air compressor failure

In the event of damage to the air compressor line, the pressure regulator has a built-in check valve to
prevent air escaping from the reservoir system.
In the event of air compressor or engine failure, the reservoir system can be supplied with compressed
air via the external filling connection.
* Semitrailer tractors with semi-pneumatic suspension (function diagram 81.99131-0558/0559) are

equipped with a 10-bar air suspension system. This vehicle is not fitted with an overflow valve with
limited return flow (G6.6) and there is no air reservoir in the air suspension system.
RA - P 85 1.62 - 3
TESTING THE BRAKE SYSTEM
Checking the reservoir circuits
The outputs of the multi-circuit protection valve have numbers on them. With the help of these numbers,
the lines can be followed in order to determine which reservoir belongs to which circuit.
Reservoir circuit and multi-circuit protection valve combinations
Multi-circuit protection valve, output (21) = Air outlet to the reservoirs, reservoir circuit I
(22) = Air outlet to the reservoirs, reservoir circuit II
(23) = Air outlet to reservoir circuit III
(24) = Air outlet to supply of pneumatic emergency release
device and to reservoir for auxiliary consumers
Checking the multi-circuit protection valve
Checking the service brake system protection for defects in circuits III and IV.
Charge the entire system until the cut-off pressure is reached and stop the engine.
Quickly reduce the pressure in circuits III and IV to 0 bar (by means of drain valve on compressed air
reservoir).
The pressure in circuits I and II must not fall below 5.0 to 4.5 bar.
Further reduce the pressure in circuits I and II by approx. 1 bar by operating the brake.
Charge the system, ensuring that a pressure of approx. 7 bar is reached in circuits I and II before the
other circuits (I or II and IV) are charged.
Checking the protection of a circuit in the service brake system for defects in another circuit of the
service brake system.
Charge the system until the cut-off pressure is reached.

Stop the engine
Quickly reduce the pressure in one of the service brake system circuits to 0 bar (by means of drain
valve on compressed air reservoir).
The warning light must come on at 5.4 bar at the latest.
Ensure that the pressure in the other circuit of the service brake system does not fall below 4.5 bar.
Fully actuate the brake twice to further reduce the pressure in the compressed air reservoir of the intact
circuit.
Hold the previously charged circuit of the service brake system open to the atmosphere and recharge
the closed circuit of the service brake system. A pressure of approx. 7 bar must be reached in the
closed circuit.
Perform this test on both circuits of the service brake system.
1.62 - 4 RA - P 85
TESTING THE BRAKING EFFECT
TESTING THE BRAKING EFFECT
TESTING AND CALCULATING THE BRAKING RATE ON THE CHASSIS DYNAMOMETER:

29 SP (special inspection), checking vehicles, here brake system
The minimum brake values defined in amendment 94/23/EC to EU Directive 77/143/EEC have been
adopted as national law.
Minimum braking rate and permissible control forces
Vehicle class Service brake system Parking brake system

z (%) FH (daN) FN (daN) z (%) FH (daN) FN (daN)
M3 50 70 18 60 70
For solo vehicle
M3 50 70 12 60 70
Total combination without
effect of trailer
The minimum braking rate is at least 50% of the basic value.

The model-specific basic values are listed in Repair Manual P 0.
Auxiliary braking effect
Vehicle class Auxiliary braking effect

M3 ( 10t), N3 Corresponding to type II, 71/320/EEC Annex II
M3 (> 10t) Corresponding to type IIa, 71/320/EEC
Annex II
NOTES ON TESTING: The pressures given in bar are excess pressures.
1. Connect precision pressure gauge (0 to 10 bar) to the test connection of the brake circuit concerned.
The deduction for the required pressure for applying the brake shoe is defined as 0.4 bar in the
formula. The maximum permissible pressure before the brake shoes are applied is 0.5 bar.
2. Effectiveness test (projection)

Preparations and testing
Charge the system until the cut-off pressure is reached
Connect the pressure gauge to the brake cylinder on the front axle(s) and rear axle(s)
(also to the leading axle / trailing axle, if fitted)
Locate the blocking limit
Read off the brake cylinder pressure when blocking occurs
Subtract at least 0.5 bar from this pressure
Example: If pressure is 2.8 bar when blocking occurs, the brake cylinder pressure for testing the
axle is 2.3 bar
When testing the axles, read off the brake cylinder pressure and brake powers and enter them on
data sheet SD 400
Use these values for the projection or use the basic values.
Calculation pressures for projection 8.0 bar
RA - P 85 1.62 - 5
OVERVIEW, BRAKE INSTALLATION DIAGRAMS
Installation diagrams
Overview for
Trucks, vehicles with leaf and air suspension
18 t to 41 t gross vehicle weight
Pneumatically braked front and rear axles
With LUCAS - D-ELSA disc brakes on front, leading, trailing and rear axles
Vehicle Function Installation Trailer brake Air suspension Date Page

models diagram diagram connection
81.99131. 81.99133.
with without with without
H 05/H 09/ 0651 0699
H 12 Sheet 1 X X 3.01 1.71-1
18.xxx FL/FLL with ECAM
truck/semitrailer
H 05/H 09/ 0651 or 0750 0699
H 12 Sheet 2 X X 02.01 1.71-2
18.xxx FL/FLL with air dryer
truck/semitrailer
H 17/H 20 0656 or 0657, 0700
26.xxx 0081 Engl. Sheet 1 X X 03.01 1.73-1
FNL/FNLL 0184 Norw. with ECAM
truck/tipper
H 17/H 20 0657 or 0750 0700
26.xxx 0184 Norw. Sheet 2 X X 03.01 1.73-2
FNL/FNLL with air dryer
truck/tipper
H 05/H 09 0650/.0651 0701
18.xxx FL/FLL 0081 Engl. Sheet 1 X X 03.01 1.75-1
truck/tipper 0184 Norw. with ECAM
H 05/H 09 0651 0701
18.xxx FL/FLL 0184 Norw. Sheet 2 X X 03.01 1.75-2
truck/tipper with air dryer
H 05/H 09 0650/.0651 0704
H 05/H 09 0650/.0651 0704
truck/tipper 0184 Norw. with air dryer
H 05/H 09/ 0651 0706
H 12 Sheet 1 X X 07.02 1.79-1
18.xxx FL/FLL with ECAM
truck/
semitrailer
H 05/H 09/ 0651 or 0750 0706
H 12 Sheet 2 X X 07.02 1.79-2
18.xxx FL/FLL with air dryer
truck/
semitrailer
RA - P 85 1.70 - 1

81.99131. 81.99133.
H 02 0729/0730 0707
18.xxx F/FK 0743/0744 Sheet 1 X X 02.02 1.81-1
H 02 0729/0730 0707
18.xxx F/FK 0743/0744 or Sheet 2 X X 09.02 1.81-2
truck/tipper 0750 with air dryer
0184 Norw.
H 02 0729/0730 0708
18.xxx F/FK 0743/0744 Sheet 1 X X 02.02 1.83-1
truck/tipper 0081 Engl. with ECAM
H 02 0729/0730 0708
18.xxx F/FK 0743/0744 or Sheet 2 X X 02.02 1.83-2
truck/tipper 0750 with air dryer
0081 Engl.
H23 0710 X
26.xxx FPL 0738 Sheet 1 X with non- 01.02 1.85-1
lifting
truck/semitrailer with ECAM leading
axle
H23 0710 X
26.xxx FVL 0738 Sheet 2 X with 01.02 1.85-2
lifting
axle
H 05/H 09 0712
18.xxx FL/FLL 0651/0751 Sheet 1 X X 07.01 1.87-1
truck/semitrailer with ECAM
H23 0730 X
26.xxx FPL 0738 Sheet 1 X with non- 01.02 1.87-2
lifting
truck/semitrailer 0081 Engl. with ECAM leading
axle
H23 0730 X
26.xxx FVL 0738 Sheet 2 X with 01.02 1.89-1
lifting
axle
H23 0731 X
26.xxx FPL 0738/0739 Sheet 1 X with non- 01.02 1.89-2
lifting
truck/tipper 0184 Norw. with ECAM leading
axle
H23 0738/0739 0731 X

26.xxx FPL or 0750 Sheet 2 X with non- 01.02 1.91-1
lifting
truck/tipper 0184 Norw. with air dryer leading
axle
H 17/H 20 0656/0657 0741

26.xxx 0081 Engl. Sheet 1 X X 02.01 1.91-2
FNL/FNLL 0184 Norw. with ECAM
truck/tipper
H 17/H 20 0656/0657 0741
26.xxx or 0750 Sheet 2 X X 09.02 1.93-1
FNL/FNLL 0081 Engl. with air dryer
truck/tipper 0184 Norw.
H25 0745
26./33.xxx FD 0754/0756 Sheet 1 X X 02.02 1.93-2
truck/ 0184 Norw. with ECAM
semitrailer
1.70 - 2 RA - P 85

81.99131. 81.99133.
H25 0745
26./33.xxx FD 0754/0756 Sheet 2 X X 02.02 1.95-1
truck/semitrailer 0184 Norw. with air dryer
H25 0754/0755/ 0746
26./33.xxx FD 0756/0757 Sheet 1 X X 02.02 1.95-2
H25 0754/0756 0746
26./33.xxx FD or 0750 Sheet 2 X X 09.02 1.97-1
truck/tipper 0184 Norw. with air dryer
H 29 0751
26./33.xxx 0764/766 Sheet 1 X X 12.01 1.97-2
FDL/FDLL with ECAM
truck/tipper
H 29 0751
26./33.xxx 0754 Sheet 2 X X 09.02 1.99 -1
FDL/FDLL with air dryer
truck/tipper
H 29 0752
26./33.xxx 0764/0766 Sheet 1 X X 12.01 1.99-2
FDL/FDLL 0184 Norw. with ECAM
truck/semitrailer
H 29 0752
26./33.xxx 0754 Sheet 2 X X 12.01 2.01-1
FDL/FDLL with air dryer
truck/semitrailer
H 23 0753
26.xxx 0738/0739 Sheet 1 X X 01.02 2.01-2
FVL/FVLL 0184 Norw. with ECAM
truck/tipper
H 23 0772/0773 0753
26.xxx 0774/0775 Sheet 2 X X 01.02 2.03-1
FVL/FVLL 0184 Norw. with air dryer
truck/tipper ??????
H36 0772/0773 0754
32./35.xxx 0774/0775 Sheet 1 X X 03.02 2.03-2
FFD/FFDK 0184 Norw. with ECAM
truck/tipper
H36 0772/0773 0754
32./35.xxx 0774/0775 or Sheet 2 X X 03.02 2.05-1
FFD/FFDK 0750 with air dryer
H25 0754/0.0755 0755
26./33.xxx 0756/0757 Sheet 1 X X X 02.02 2.05-2
FD/FDK 0184 Norw. with ECAM
truck/tipper
H 25 0755
26./33.xxx 0754/0756 Sheet 2 X X X 02.02 2.07-1
FD/FDK or 0750 with air dryer
RA - P 85 1.70 - 3

81.99131. 81.99133.
H 25 0756
26./33.xxx 0754/0756 Sheet 1 X X 02.02 2.07-2
FDR/FDRS 0184 Norw. with ECAM
truck/semitrailer
H 25 0756
26./33.xxx 0754/0756 Sheet 2 X X 02.02 2.09-1
FDR/FDRS or 0750 with air dryer
truck/semitrailer 0184 Norw.
H40 0772/0773 0757
32./35.xxx 0774/0775 Sheet 1 X X 04.02 2.09-2
FFD/FFDLG 0184 Norw. with ECAM
truck/tipper
H40 0772/0773 0757
32./35.xxx 0774/0775 or Sheet 2 X X 04.02 2.11 - 1
FFD/FFDLG 0750 with air dryer
H40 0772/0773 0758
32./35.xxx 0774/0775 Sheet 1 X X 04.02 2.11 - 2
FFD/FFDLG 0184 Norw with ECAM
truck/tipper
H40 0772/0773 0758
32./35.xxx 0774/0775 or Sheet 2 X X 04.02 2.13 - 1
FFD/FFDL 0750 with air dryer
H 23 0768 X
26.xxx 0738 Sheet 1 X with 10.02 2.13 - 2
lifting
FVL/FVLL with ECAM leading
truck/semitrailer axle
H 23 0768 X
26.xxx 0738 Sheet 2 X with 10.02 2.15 - 1
lifting
FVL/FVLL with air dryer leading
H 23 0769 X
26.xxx 0738 Sheet 1 X with 10.02 2.15 - 2
lifting
FVL/FVLL with ECAM leading
H 23 0769 X
26.xxx 0738 Sheet 2 X with 10.02 2.17 - 1
lifting
FVL/FVLL with air dryer leading
1.70 - 4 RA - P 85
KEY
Keys to installation diagram, 81.99133.0699, for trucks/semitrailers, model H05/H09/H12, 18.xxx

FL/FLLwith ECAM system, sheet 1, as of: 03. 01
Note:
1. See device list 81.52100.8930 for device names
2. The key is split up into several sections. It consists of the basic version (without trailer, without air
springs), the supplementary key: 1. With trailer; 2. With semitrailer; 3. With air springs; and the
supplements without G no. (device no.)
3. G X.F brake devices: See vehicle-specific brake function diagram.
Key (without trailer, without air springs) Supplements without G no. (device no.)
G 1.2 Air compressor, optional one/two- 008 Reservoir line to air suspension (see
cylinder installation diagram, air suspension)
G 5.121 Safety valve, 17 + 2 bar 012 Coupling head, reservoir (red)
G 7.F Service brake valve 013 Coupling head, brake (yellow)
2-circuit tandem valve
020 See installation diagram, air suspension
G 10.F Diaphragm brake cylinder
021 Auxiliary consumers (see separate
G 11.F Combination brake cylinder installation diagrams)
G 14.F PA relay valve 022 See installation diagram, installation in
the cab
G 25.F Electronically controlled air management
(ECAM) 023 Distributor, pedal plate
G 50.F Compressed air reservoir 024 Distributor
G 51.3 Drain valve with pin, without ring 025
G 53.3 Filling valve 026
G 54.F Test connections 027
G 55.F Pressure switch, pneumatic 028 See installation diagram, brake hoses
G 56.2 Compressed air cylinder for exhaust flap 029 See installation diagram
G 61.200 Solenoid valve, air in, NW 2.2
3/2-way valve (auxiliary brake system)
G 67.F Pressure control module
Supplement 1 (with trailer)
G 17.F Trailer control module
G 19.3 Coupling head, 2-line, reservoir, red
G 19.4 Coupling head, 2-line, brake, yellow
G 19.30 Dead coupling, 2-line
G 29.3 Serpentine hose unions,
reservoir/brake (black)
1.70 - 6 RA - P 85
INSTALLATION DIAGRAM
Brake system installation diagram no.: 81.99133.0699, as of: 03. 2001, Sheet 1, for trucks/semitrailers, model H 05/H 09/H12, 18.xxx FL/FLL, left-hand drive with ECAM system, with air suspension, with and without trailer brake.
Repair note: If possible, use devices made by the same manufacturer when exchanging devices.
RA - P 85 1.71 - 1
KEY
Keys to installation diagram, 81.99133.0699, for trucks/semitrailers, model H 05/H 09/H12,

18.xxx FL/FLL, with air dryer, sheet 2, as of: 02. 01
Note:
suspension) and the following supplementary keys: 1. With trailer; 2. With semitrailer; 3. With air
springs; and the supplements without G no. (device no.)
G 4.7 Multi-circuit protection valve, 013 Coupling head, brake (yellow)
5 connections
G 5.200 Pressure limiting valve, 8.5 - 0.4 bar
G 5.201 Pressure limiting valve, 10 0.3 bar installation diagrams)
G 7.F Service brake valve 022 See installation drawing, installation in
2-circuit tandem valve the cab
G 10.F Diaphragm brake cylinder 023 Distributor, pedal plate
G 11.F Combination brake cylinder 024 Distributor
G 14.F PA relay valve 025
G 23.201 Double check valve 026
G 25.2F Air dryer with pressure regulator 027
(changeover cartridge, with heating) 028 See installation drawing, brake hoses
G 50.F Compressed air reservoir 029 See installation drawing
G 50. 40 Compressed air reservoir, 4l, 12.5 bar
(clean-air reservoir)
G 51.3 Drain valve with pin, without ring
G 53.3 Filling valve
G 54.F Test connections
G 55.F Pressure switch, pneumatic
G 56.2 Compressed air cylinder for exhaust flap
G 57.F Pressure gauges/pressure sensors
G 19.3 Coupling head, 2-line, reservoir, red
G 29.3 Serpentine hose unions,
G 51.3 Drain valve with pin
without ring
RA - P 85 1.72 -1
Brake system installation diagram no.: 81.99133.0699, as of: 02. 01, Sheet 2, for trucks/semitrailers, model H 05/H 09/H12, 18.xxx FL/FLL, left-hand drive with air dryer, with air suspension, with and without trailer brake.
021
1.71 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0700, for trucks/tippers, model H 17/H 20, 26.xxx FNL/FNLL;
with ECAM system, sheet 1, as of: 03. 01
Note:
springs) and the following supplementary keys: 1. With trailer; 2. With semitrailer; 3. With air springs;
and the supplements without G no. (device no.)
Key (without trailer, without air springs) Supplement 1 (with trailer)
G 1.2 Air compressor, optional one/two- G 17.F Trailer control module
cylinder
G 19.3 Coupling head, 2-line reservoir, red
G 5.121 Safety valve, 17 + 2 bar
G 7.F Service brake valve,
Supplements without G no. (device no.)
G 10.F Diaphragm brake cylinder 008 Reservoir line to air suspension (see
installation diagram, air suspension)
G 11.F Combination brake cylinder
012 Coupling head, reservoir (red)
G 14.66 Relay valve with adjustable lead
(0.4 bar) 013 Coupling head, brake (yellow)
G 14.300 PA relay valve 014 Dummy plug without coupling head
G 21.11 Double-check valve, low pressure- 020 See installation diagram, air suspension
opened (2-way valve) 021 Auxiliary consumers (see separate
G 25.F Electronically controlled air management installation diagrams)
(ECAM) 022 See installation drawing, installation in
G 50.F Compressed air reservoir the cab
G 51.3 Drain valve with pin, without ring 023 Distributor, pedal plate
G 53.3 Filling valve 024 Distributor
G 55.200 Pressure switch, pneumatic 026
G 56.2 Compressed air cylinder for exhaust flap 027
G 61.200 Solenoid valve, air in, NW 2.2 028 See installation drawing, brake hoses
3/2-way valve (auxiliary brake system) 029 See installation drawing
G 67.F Pressure control module 045 = with trailer brake
1.72 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0700, as of: 03.01, Sheet 1, for trucks/tippers, model H 17/H 20, 26.xxx FNL/FNLL, with ECAM system, with air suspension, with and without trailer brake.
RA - P 85 1.73 - 1
KEY
Keys to installation diagram, 81.99133.0700, for trucks/tippers, model H 17/H 20, 26.xxx FNL/FNLL,
with air dryer, sheet 2, as of: 03. 01
Note:
springs), the additional keys: 1. with trailer, 2. with semitrailer, 3. with air springs and the supplements
without device number (G number).
G 4.7 Multi-circuit protection valve, 013 Coupling head, brake (yellow)
5 connections
014 Dummy plug without coupling head
G 5.201 Pressure limiting valve, 10 0.3 bar 021 Auxiliary consumers (see separate
G 7.F Service brake valve installation diagrams)
2-circuit tandem valve 022 See installation drawing, installation in
G 10.F Diaphragm brake cylinder the cab
G 11.F Combination brake cylinder 023 Distributor, pedal plate
G 14.66 Relay valve with adjustable lead 024 Distributor
(0.4 bar) 025 Clean-air reservoir
G 14.300 PA relay valve 026
G 21.11 Double-check valve, low pressure- 027
opened (2-way valve)
028 See installation drawing, brake hoses
G 23.201 Double check valve
029 See installation drawing
G 25.2F Air dryer with pressure regulator
(changeover cartridge, with heating) 045 = with trailer brake
G 50.F Compressed air reservoir
G 55.200 Pressure switch, pneumatic
without ring
RA - P 85 1.74 -1
1.73 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0701, for trucks/tippers, model H05/H09, 18. xxx FL/FLL
with ECAM system, sheet 1, as of: 03. 01,
Note:
suspension) and the following supplementary keys: 1. With trailer; 2. With semitrailer; 3. With air
springs; and the supplements without G no. (device no.)
G 14.F Relay valve installation diagrams)
G 25.F Electronically controlled air management 022 See installation drawing, installation in
(ECAM) the cab
G 50.F Compressed air reservoir 023 Distributor, pedal plate
G 51.3 Drain valve with pin, without ring 024 Distributor
G 55.F Pressure switch, pneumatic 027
G 56.2 Compressed air cylinder for exhaust flap 028 See installation drawing, brake hoses
G 61.200 Solenoid valve, air in, NW 2.2 029 See installation drawing
3/2-way valve (auxiliary brake system) 045 = with trailer brake
1.74 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0701, as of 03. 01 Sheet 1 for trucks/tippers, model H 05/H 09, 18.xxx FL/FLL, with ECAM system, with air suspension, with and without trailer brake
RA - P 85 1.75 - 1
KEY
with air dryer, sheet 2, as of: 03. 01,
Note:
G 4.7 Multi-circuit protection valve, 012 Coupling head, reservoir (red)
5 connections
013 Coupling head, brake (yellow)
G 14.F Relay valve, 024 Distributor
G 23.201 Double check valve 025 Clean-air reservoir
(changeover cartridge, with heating) 027
G 50.F Compressed air reservoir 028 See installation drawing, brake hoses
G 50. 40 Compressed air reservoir, 4l, 12.5 bar 029 See installation drawing
G 51.3 Drain valve with pin, without ring 045 = with trailer brake

without ring
RA - P 85 1.76 -1
Brake system installation diagram no.: 81.99133.0701, as of 03. 01 Sheet 2 for trucks/tippers, model H 05/H 09, 18.xxx FL/FLL, with air dryer, with air suspension, with and without trailer brake
1.75 - 2 RA - P 85
KEY
Note:
(ECAM) the cab
1.76 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0704, as of: 03.01, Sheet 1, for trucks/tippers, model H 05/H 09, 18.xxx FL/FLL, with ECAM system, with air suspension, with and without trailer brake.
RA - P 85 1.77 - 1
KEY
Note:
5 connections

without ring
RA - P 85 1.78 -1
Brake system installation diagram no.: 81.99133.0704, as of: 03.01, Sheet 2, for trucks/tippers, model H 05/H 09, 18.xxx FL/FLL, with air dryer, with air suspension, with and without trailer brake.
1.77 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0706, for trucks/semitrailers, model H05/H09, 18. xxx FL/FLL
Note:
014
(ECAM) the cab
G 29. 3 Serpentine hose unions,
reservoir/brake (black) for semitrailer
1.78 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0706, as of: 07.02, Sheet 1, for trucks/semitrailers, model H 05/H 09, 18.xxx FL/FLL, with ECAM system, with air suspension, with and without trailer brake.
RA - P 85 1.79 - 1
KEY
Keys to installation diagram, 81.99133.0706, for trucks/semitrailers, model H05/H09, 18.xxx FL/FLL
Note:
5 connections
014
G 29. 3 Serpentine hose unions, reservoir/brake
(black) for semitrailer
without ring
RA - P 85 1.80 -1
Brake system installation diagram no.: 81.99133.0706, as of: 07.02, Sheet 2, for trucks/tippers, model H 05/H 09, 18.xxx FL/FLL, with air dryer, with air suspension, with and without trailer brake.
1.79 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0707, for trucks/tippers, model H02, 18.xxx F/FK
Note:
G 1.2 Air compressor, optional one/two- 012 Coupling head, reservoir (red)
cylinder
G 5.67 Pressure limiting valve 20/3.5 +0.2 bar
G 7.F Service brake valve
installation diagrams)
022 See installation drawing, installation in
G 11.F Combination brake cylinder the cab
G 14.F Relay valve 023 Distributor, pedal plate
G 25.F Electronically controlled air management 024 Distributor
(ECAM)
025 Installation only if drum brake fitted
026 See installation drawing, test
G 51.3 Drain valve with pin, without ring connections on battery box
G 53.3 Filling valve 027 See installation drawing, test
connections on rear axle
045 = with trailer brake
1.80 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0707, as of: 02.02, Sheet 1, for trucks/semitrailers, model H 02, 18.xxx F/FK, with ECAM system, with air suspension, with and without trailer brake.
RA - P 85 1.81 - 1
KEY
Note:
cylinder
G 4.7 Multi-circuit protection valve,
5 connections
G 5.201 Pressure limiting valve, 10 0.3 bar the cab
G 7.F Service brake valve 023 Distributor, pedal plate
2-circuit tandem valve 024 Distributor
G 10.F Diaphragm brake cylinder 025 Installation only if drum brake fitted
G 11.F Combination brake cylinder 026 See installation drawing, test
G 14.F Relay valve, connections on battery box
G 23.201 Double check valve 027 See installation drawing, test
G 25.2X Air dryer with pressure regulator
G 50. 40 Compressed air reservoir, regeneration, 040 = only with trailer brake
4l, 12.5 bar 045 = with trailer brake
G 50. 40 Compressed air reservoir (circuit III,

trailer brake) 4l, 12.5 bar
without ring
RA - P 85 1.82 -1
Brake system installation diagram no.: 81.99133.0707, as of: 09.02, Sheet 2, for trucks/semitrailers, model H 02, 18.xxx F/FK, with air dryer, with air suspension, with and without trailer brake.
1.81 - 2 RA - P 85
KEY
Note:
cylinder
G 7.F Service brake valve
G 14.F Relay valve 023 Distributor, pedal plate
(ECAM)
G 51.3 Drain valve with pin, without ring connections on battery box
1.82 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0708, as of: 02.02, Sheet 1, for trucks/tippers, model H 02, 18.xxx F/FK, with ECAM system, with leaf suspension, with and without trailer brake.
RA - P 85 1.83 - 1
KEY
Note:
cylinder
5 connections
G 7.F Service brake valve 023 Distributor, pedal plate
2-circuit tandem valve 024 Distributor
G 10.F Diaphragm brake cylinder 025 Installation only if drum brake fitted
G 11.F Combination brake cylinder 026 See installation drawing, test
G 14.F Relay valve, connections on battery box
G 23.201 Double check valve 027 See installation drawing, test
G 50. 40 Compressed air reservoir, regeneration, 040
4l, 12.5 bar 045 = with trailer brake
G 50. 40 Compressed air reservoir (circuit III,
trailer brake) 4l, 12.5 bar
without ring
RA - P 85 1.84 -1
Brake system installation diagram no.: 81.99133.0708, as of: 02.02, Sheet 2, for trucks/tippers, model H 02, 18.xxx F/FK, with air dryer, with leaf suspension, with and without trailer brake.
1.83 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0710, for trucks/semitrailers, model H23 , 26.xxx FPL
with ECAM system and non-lifting leading axle, sheet 1, as of: 01. 02,
Note:
G 1.2 Air compressor, optional one/two- 008 Line to air suspension (see installation
cylinder diagram, air suspension)
G 5.1 Pressure limiting valve, 10/0.3 -0.2 bar 012 Coupling head, reservoir (red)
G 5.121 Safety valve, 17 + 2 bar 013 Coupling head, brake (yellow)
G 7,301 Service brake valve, EBS 014 Dummy plug without coupling head
G 10.F Diaphragm brake cylinder 020 See installation diagram, air suspension
G 11.F Combination brake cylinder 021 Auxiliary consumers (see separate
G 14.66 Relay valve with lead, 0.4 bar,
connection 3 = M 22 x 1.5 022 See installation drawing, installation in
the cab
G 14.300 PA relay valve
023 Distributor, pedal plate
G 21.11 Double check valve,
opening at low pressure 024 Distributor
G 24.9 Vent valve, pneumatically controlled 025
(Europe valve)
G 25.F Electronically controlled air management connections on battery box
(ECAM)
G 27.63 Silencer (M 22 x 1.5) connections on rear axle
G 50. 305 Compressed air reservoir (circuit, service 029 See installation drawing
brake system-rear axle)
030 See installation drawing, large battery
G 53.3 Filling valve box
G 55.F Pressure switch, pneumatic 031 See installation drawing, small battery
box
G 55.300 Pressure sensor, NC contact,
5.8 - 0.4 bar 045 = with trailer brake
G 73.230 Solenoid valve, ECAS

1.84 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0710, as of: 01.02, Sheet 1, for trucks/semitrailers, model H 23, 26.xxx FVL/FVLS, with ECAM system, with air suspension, with non-lifting leading axle, with and without trailer brake.
RA - P 85 1.85 - 1
KEY
Keys to installation diagram, 81.99133.0710, for trucks/semitrailers, model H23, 26.xxx FVL
with ECAM system and lifting leading axle, sheet 2, as of: 01. 02,
Note:
G 7.301 Service brake valve, EBS 014 Dummy plug without coupling head
the cab
G 21.F Double check valve,
G 25.F Electronically controlled air management 025
(ECAM)
G 27.63 Silencer (M 22 x 1.5) connections on battery box
G 50.F Compressed air reservoir 027 See installation drawing, test
G 50. 305 Compressed air reservoir (circuit, service
brake system-rear axle) 028 See installation drawing, brake hoses
G 53.3 Filling valve 029 See installation drawing
G 55.300 Pressure sensor, NC contact, 030 See installation drawing, large battery
5.8 - 0.4 bar box
G 56.2 Compressed air cylinder for exhaust flap 031 See installation drawing, small battery
box

RA - P 85 1.86 -1
Brake system installation diagram no.: 81.99133.0710, as of: 01.02, Sheet 2, for trucks/semitrailers, model H 23, 26.xxx FVL/FVLS, with air dryer, with air suspension, with lifting leading axle, with and without trailer brake.
1.85 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0712, for trucks/semitrailers, model H05/H09, 18.xxx FL/FLL
with ECAM system under battery box, sheet 1, as of: 07. 01,
Note:
G 10.F Diaphragm brake cylinder 014
G 11.F Combination brake cylinder 020 See installation diagram, air suspension
G 14.F Relay valve 021 Auxiliary consumers (see separate
(ECAM) 022 See installation drawing, installation in
the cab
024 Distributor
025
026
027
3/2-way valve (auxiliary brake system) 028 See installation drawing, brake hoses
G 67.F Pressure control module 029 See installation drawing
030
031
045
1.86 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0712, as of: 07.01, Sheet 1, for trucks/semitrailers, model H 05/H 09, 18.xxx FL/FLLS, with ECAM system, with air suspension, with and without trailer brake.
RA - P 85 1.87 - 1
KEY
Keys to installation diagram, 81.99133.0730, for trucks/semitrailers, model H23, 26.xxx FPL
Note:
the cab
(Europe valve)
(ECAM)
G 27.63 Silencer (M 22 x 1.5) connections on rear axle
G 50. 305 Compressed air reservoir (circuit, service 029 See installation drawing
G 53.3 Filling valve box
G 55.F Pressure switch, pneumatic 031 See installation drawing, small battery
box

RA - P 85 1.88 -1
Brake system installation diagram no.: 81.99133.0730, as of: 01.02, Sheet 1, for trucks/semitrailers, model H 23, 26.xxx FPL/FPLS, with ECAM system, with air suspension, with non-lifting leading axle, with and without trailer brake.
1.87 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0730, for trucks/semitrailers, model H23, 26.xxx FPL
Note:
G 7.301 Service brake valve, EBS 014
the cab
(ECAM)
5.8 - 0.4 bar box
box

1.88 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0730, as of: 01.02, Sheet 2, for trucks/semitrailers, model H 23, 26.xxx FVL/FVLS, with ECAM system, with air suspension, with lifting leading axle, with and without trailer brake.
RA - P 85 1.89 - 1
KEY
Keys to installation diagram, 81.99133.0731, for trucks/tippers, model H23, 26.xxx FPL
Note:
the cab
(Europe valve)
(ECAM)
G 50.F Compressed air reservoir connections on rear axle
G 50. 305 Compressed air reservoir (circuit, service 028 See installation drawing, brake hoses
G 55.F Pressure switch, pneumatic box
G 55.200 Pressure sensor, NC contact, 031 See installation drawing, small battery
5.8 - 0.4 bar box
G 56.2 Compressed air cylinder for exhaust flap 041 Ventilation - routed in frame
G 61.200 Solenoid valve, air in, NW 2.2 045 = with trailer brake

RA - P 85 1.90 -1
Brake system installation diagram no.: 81.99133.0731, as of: 01.02, Sheet 1, for trucks/tippers, model H 23, 26.xxx FPL, with ECAM system, with air suspension, with non-lifting leading axle, with and without trailer brake.
1.89 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0731, for trucks/tippers, model H23, 26.xxx FPL
with air dryer and non-lifting leading axle, sheet 2, as of: 01. 02,
Note:
G 1.2 Air compressor, optional one/two-cylinder 008 Line to air suspension (see installation
diagram, air suspension)
G 5.1 Pressure limiting valve, 10/0.3 -0.2 bar
G 5.201 Pressure limiting valve, 10 0.3 bar
G 7.301 Service brake valve, EBS
G 10.F Diaphragm brake cylinder installation diagrams)
G 11.F Combination brake cylinder 022 See installation drawing, installation in
G 14.66 Relay valve with lead, 0.4 bar, the cab
connection 3 = M 22 x 1.5 023 Distributor, pedal plate
G 14.300 PA relay valve 024 Distributor
G 21.F Double check valve, 025
opening at low pressure
G 23.202 Non-return valve (bulkhead union) connections on battery box
G 24.9 Vent valve, pneumatically controlled 027 See installation drawing, test
(Europe valve) connections on rear axle
G 25.2F Air dryer with pressure regulator 028 See installation drawing, brake hoses
(changeover cartridge, with heating)
G 50. 40 Compressed air reservoir (regeneration) box
G 53.3 Filling valve 031 See installation drawing, small battery
G 55.F Pressure switch, pneumatic box
G 55.200 Pressure sensor, NC contact, 041 Ventilation - routed in frame

G 50. 40 Compressed air reservoir
(circuit III, trailer brake)
1.90 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0731, as of: 01.02, Sheet 2, for trucks/tippers, model H 23, 26.xxx FPL, with air dryer, with air suspension, with non-lifting leading axle, with and without trailer brake.
RA - P 85 1.91 - 1
KEY
Keys to installation diagram, 81.99133.0741, for trucks/tippers, model H17/H20, 26.xxx FNL/FNLL
Note:
G 10.F Diaphragm brake cylinder 014 Dummy plug without coupling head
G 14.66 Relay valve with lead, 0.4 bar, 021 Auxiliary consumers (see separate
connection 3 = M 22 x 1.5 installation diagrams)
G 14.300 PA relay valve 022 See installation drawing, installation in
the cab
G 21.11 Double check valve (opening at low
pressure) 023 Distributor, pedal plate
(ECAM)
025
026
027
G 55.200 Pressure sensor, NC contact, 028 See installation drawing, brake hoses
5.8 - 0.4 bar
030
3/2-way valve (auxiliary brake system) 031
G 67.F Pressure control module 040 Only with trailer brake
041
Supplement 1 (with trailer) 045 = with trailer brake
RA - P 85 1.92 -1
1.91 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0741, for trucks/tippers, model H17/H20, 26.xxx FNL/FNLL
with air dryer and non-lifting leading axle, sheet 2, as of: 01. 02,
Note:
5 connections
G 10.F Diaphragm brake cylinder 022 See installation drawing, installation in
the cab
connection 3 = M 22 x 1.5 024 Distributor
G 21.11 Double check valve, 026
opening at low pressure 027
G 23.201 Double check valve 028 See installation drawing, brake hoses
G 25.2F Air dryer with pressure regulator 029 See installation drawing
030
031
G 50. 40 Compressed air reservoir (regeneration)
040 Only with trailer brake
041
5.8 - 0.4 bar

1.92 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0741, as of: 03.01, Sheet 2, for trucks/tippers, model H 17/H 20, 26.xxx FNL/FNLL, with air dryer, with air suspension, with and without trailer brake.
RA - P 85 1.93 - 1
KEY
Keys to installation diagram, 81.99133.0745, for trucks/semitrailers, model H25, 26./33.xxx FD

with ECAM system and leaf suspension, sheet 1, as of: 02. 02,
Note:
G 1.2 Air compressor, optional one/two- 008
cylinder
G 5.67 Pressure limiting valve, 20/3.5 + 0.2 bar
(only if drum brake fitted)
020
G 7.301 Service brake valve (EBS)
G 14.F Relay valve the cab
G 14.300 PA relay valve 023 Distributor, pedal plate
(ECAM)
G 53.3 Filling valve connections on battery box
G 55.200 Pressure sensor, NC contact, 027
5.8 - 0.4 bar 028 See installation drawing, brake hoses
G 56.2 Compressed air cylinder for exhaust flap 029 See installation drawing
G 61.200 Solenoid valve, air in, NW 2.2 030
031
040
041
045
050 = PA lines for compressed air reservoir,
G 19.4 Coupling head, 2-line, brake, yellow depending on wheelbase
RA - P 85 1.94 -1
Brake system installation diagram no.: 81.99133.0745, as of: 02.02, Sheet 1, for trucks/semitrailers, model H 25, 26/33.xxx FD, with ECAM system, with leaf suspension, with and without trailer brake.
1.93 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0745, for trucks/semitrailers, model H25, 26./33.xxx FD

with air dryer and leaf suspension, sheet 2, as of: 02. 02,
Note:
G 1.2 Air compressor, optional one/two-cylinder 008
5 connections
020
G 5.201 Pressure limiting valve, 10 0.3 bar 022 See installation drawing, installation in
G 7.301 Service brake valve, EBS the cab
G 14.F Relay valve 025 Installation only if drum brake fitted
G 14.300 PA relay valve 026 See installation drawing, test
connections on battery box
027
G 25.F Air dryer with pressure regulator
G 50. 40 Compressed air reservoir (regeneration) 030
not if 2-chamber air dryer is fitted 031
G 53.3 Filling valve 032 Not if 2-chamber air dryer is fitted
G 55.F Pressure switch, pneumatic 033 If 2-chamber air dryer is fitted
G 55.200 Pressure sensor, NC contact, 038 Only for wheelbase R3200, R4200,
5.8 - 0.4 bar R4500, R5100
G 57.F Pressure gauges/pressure sensors 045
G 61.200 Solenoid valve, air in, NW 2.2 050 = PA lines for compressed air reservoir,
3/2-way valve (auxiliary brake system) depending on wheelbase
1.94 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0745, as of: 02.02, Sheet 2, for trucks/semitrailers, model H 25, 26/33.xxx FD, with air dryer, with leaf suspension, with and without trailer brake.
RA - P 85 1.95 - 1
KEY
Keys to installation diagram, 81.99133.0746, for trucks/tippers, model H25, 26./33.xxx FD

Note:
cylinder
020
G 14.F Relay valve the cab
G 14.300 PA relay valve 023 Distributor, pedal plate
(ECAM)
G 53.3 Filling valve connections on battery box
031
034 Additional compressed air reservoir for
Supplement 1 (with trailer) tipper wheelbase R3600, R3900
G 17.F Trailer control module 035 Additional compressed air reservoir for
G 19.3 Coupling head, 2-line reservoir, red truck wheelbase R3900
G 19.4 Coupling head, 2-line, brake, yellow 036 Additional compressed air reservoir for
truck wheelbase R3200, from R4200
truck wheelbase R3600
040
041
depending on wheelbase
RA - P 85 1.96 -1
Brake system installation diagram no.: 81.99133.0746, as of: 02.02, Sheet 1, for trucks/tippers, model H 25, 26/33.xxx FD, with ECAM system, with leaf suspension, with and without trailer brake.
1.95 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0746, for trucks/tippers, model H25, 26./33.xxx FD

Note:
cylinder
5 connections
(only if drum brake fitted) 020
G 5.121 Safety valve, 17 + 2 bar 021 Auxiliary consumers (see separate
G 7.301 Service brake valve, EBS 023 Distributor, pedal plate
G 10.F Diaphragm brake cylinder 024 Distributor
G 11.F Combination brake cylinder 025 Installation only if drum brake fitted
G 14.F Relay valve 026 See installation drawing, test
G 14.300 PA relay valve connections on battery box
(changeover cartridge, with heating) 029 See installation drawing
G 50.F Compressed air reservoir 030
not if 2-chamber air dryer is fitted 032 Not if 2-chamber air dryer is fitted
G 53.3 Filling valve 033 If 2-chamber air dryer is fitted
G 55.F Pressure switch, pneumatic 034 Additional compressed air reservoir for
G 55.200 Pressure sensor, NC contact, tipper wheelbase R3600, R3900
5.8 - 0.4 bar 035 Additional compressed air reservoir for
G 56.2 Compressed air cylinder for exhaust flap truck wheelbase R3900
G 57.F Pressure gauges/pressure sensors 036 Additional compressed air reservoir for
3/2-way valve (auxiliary brake system) 037 Additional compressed air reservoir for
040 Only with trailer brake
041
1.96 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0746, as of: 09.02, Sheet 2, for trucks/tippers, model H 25, 26/33.xxx FD, with air dryer, with leaf suspension, with and without trailer brake.
RA - P 85 1.97 - 1
KEY
Keys to installation diagram, 81.99133.0751, for trucks/tippers, model H29, 26./33.xxx FDL
with ECAM system and air suspension, sheet 1, as of: 12. 01,
Note:
G 7.301 Service brake valve (EBS) 013 Coupling head, brake (yellow)
the cab
(ECAM)
024 Distributor
5.8 - 0.4 bar 026 See installation drawing, test
027
Supplement 1 (with trailer) 030
G 17.F Trailer control module 031
G 19.3 Coupling head, 2-line reservoir, red 034 Additional compressed air reservoir for
tipper wheelbase R3600, R3900
040
041
RA - P 85 1.98 -1
Brake system installation diagram no.: 81.99133.0751, as of: 12.01, Sheet 1, for trucks/tippers, model H 29, 26/33.xxx FDL/FDLL, with ECAM system, with air suspension, with and without trailer brake.
1.97 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0751, for trucks/tippers, model H29, 26./33.xxx FDL
Note:
G 1.2 Air compressor, optional one/two- 008 Line to reservoir, air suspension (see
5 connections
G 7.301 Service brake valve, EBS installation diagrams)
the cab
G 14.F Relay valve
024 Distributor
G 25.F Air dryer with pressure regulator connections on battery box
G 50. 40 Compressed air reservoir (regeneration) 029 See installation drawing
not if 2-chamber air dryer is fitted
030
031
032 Not if 2-chamber air dryer is fitted
5.8 - 0.4 bar 033 If 2-chamber air dryer is fitted
G 56.2 Compressed air cylinder for exhaust flap 034 Additional compressed air reservoir for
tipper wheelbase R3600, R3900
G 61.200 Solenoid valve, air in, NW 2.2 truck wheelbase R3900
G 67.F Pressure control module truck wheelbase R3200, from R4200
Supplement 1 (with trailer) 037 Additional compressed air reservoir for
G 17.F Trailer control module truck wheelbase R3600
G 19.3 Coupling head, 2-line reservoir, red 040 Only with trailer brake
G 19.4 Coupling head, 2-line, brake, yellow 041
G 50. 40 Compressed air reservoir 045 = with trailer brake
(circuit III, trailer brake) 050 = PA lines for compressed air reservoir,
G 51.3 Drain valve with pin, without ring depending on wheelbase
1.98 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0751, as of: 09.02, Sheet 2, for trucks/tippers, model H 29, 26/33.xxx FDL/FDLL, with air dryer, with air suspension, with and without trailer brake.
RA - P 85 1.99 - 1
KEY
Keys to installation diagram, 81.99133.0752, for trucks/semitrailers, model H29, 26./33.xxx FDL
Note:
G 7.301 Service brake valve (EBS) 013 Coupling head, brake (yellow)
the cab
(ECAM)
024 Distributor
5.8 - 0.4 bar 026 See installation drawing, test
027
G 19.3 Coupling head, 2-line reservoir, red semitrailer wheelbase R3600, R3900
G 19.4 Coupling head, 2-line, brake, yellow 040
G 19.30 Dead coupling, 2-line 041
G 29. 3 Serpentine hose unions, reservoir/brake 045 = with trailer brake
RA - P 85 2.00 -1
Brake system installation diagram no.: 81.99133.0752, as of: 12.01, Sheet 1, for trucks/semitrailers, model H 29, 26/33.xxx FDL/FDLL, with ECAM system, with air suspension, with and without trailer brake.
1.99 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0752, for trucks/semitrailers, model H29, 26./33.xxx FDL
Note:
G 1.2 Air compressor, optional one/two- 008 Line to reservoir, air suspension (see
5 connections
the cab
G 14.F Relay valve
024 Distributor
G 25.F Air dryer with pressure regulator connections on battery box
G 50. 40 Compressed air reservoir (regeneration) 029 See installation drawing
not if 2-chamber air dryer is fitted
G 53.3 Filling valve truck wheelbase R3200
G 55.200 Pressure sensor, NC contact, semitrailer wheelbase R3600, R3900
5.8 - 0.4 bar 040 Only with trailer brake
G 57.F Pressure gauges/pressure sensors 045 = with trailer brake
G 61.200 Solenoid valve, air in, NW 2.2 050 = PA lines for compressed air reservoir,
3/2-way valve (auxiliary brake system) depending on wheelbase
2.00 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0752, as of: 12.01, Sheet 2, for trucks/semitrailers, model H 29, 26/33.xxx FDL/FDLL, with air dryer, with air suspension, with and without trailer brake.
RA - P 85 2.01 - 1
KEY
Keys to installation diagram: 81.99133.0753, for trucks/tippers, model H23, 26.xxx FVL/FVLL
Note:
G 5.1 Pressure limiting valve 10/0.3 -0.2 bar 012 Coupling head, reservoir (red)
G 7.301 Service brake valve (EBS) 014 Dummy plug without coupling head
or installation drawing, test connections
connection 3 = M 22 x 1.5
the cab
024 Distributor
(ECAM) 025
G 55.200 Pressure sensor, NC contact, 028 See installation drawing, brake hoses
5.8 - 0.4 bar 029 See installation drawing
G 56.2 Compressed air cylinder for exhaust flap 045 = with trailer brake

RA - P 85 2.02 -1
Brake system installation diagram no.: 81.99133.0753, as of: 01.02, Sheet 1, for trucks/tippers, model H 23, 26.xxx FVL/FVLL, with ECAM system, with air suspension, with and without trailer brake.
2.01 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0753, for trucks/tippers, model H23, 26.xxx FVL/FVLL
with air dryer and lifting leading axle, sheet 2, as of: 01. 02,
Note:
G 1.2 Air compressor, optional one/two-cylinder 008 Line to reservoir, air suspension (see
installation diagram, air suspension)
5 connections 012 Coupling head, reservoir (red)
G 5.1 Pressure limiting valve 10/0.3 -0.2 bar 013 Coupling head, brake (yellow)
G 5.121 Safety valve, 17 + 2 bar 014 Dummy plug without coupling head
G 5.200 Pressure limiting valve, 8.5 - 0.4 bar 020 See installation diagram, air suspension
or installation drawing, test connections
G 5.201 Pressure limiting valve, 10 0.3 bar
G 14.66 Relay valve with lead, 0.4 bar, 023 Distributor, pedal plate
connection 3 = M 22 x 1.5 024 Distributor
G 21.F Double check valve, 026
027
G 23.202 Non-return valve (bulkhead union)
not if 2-chamber air dryer is fitted 045 = with trailer brake
5.8 - 0.4 bar
2.02 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0753, as of: 01.02, Sheet 2, for trucks/tippers, model H 23, 26.xxx FVL/FVLL, with air dryer, with air suspension, with and without trailer brake.
RA - P 85 2.03 - 1
KEY
Keys to installation diagram, 81.99133.0754, for trucks/tippers, model H36, 32./35.xxx FFD/FFDK
Note:
cylinder
020
G 14.F Relay valve, 022 See installation drawing, installation in
the cab
G 22.200 Quick-release valve
024 Distributor
(ECAM) 025 Installation only if drum brake fitted
027
G 61.200 Solenoid valve, air in, NW 2.2 041 Installation for vehicle with spare wheel
3/2-way valve (auxiliary brake system) wheelbase R 2980
G 67.F Pressure control module 042 Installation for vehicle without spare
wheel wheelbase R 2980
Supplement 1 (with trailer) 045 = with trailer brake
G 17.F Trailer control module 050 = PA lines for compressed air reservoir,
RA - P 85 2.04 -1
Brake system installation diagram no.: 81.99133.0754, as of: 03.02, Sheet 1, for trucks/tippers, model H 36, 32./35.xxx FFD/FFDK, with ECAM system, with leaf suspension, with and without trailer brake.
2.03 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0754, for trucks/tippers, model H36, 32./35.xxx FFD/FFDK
Note:
cylinder
5 connections
020
G 7.301 Service brake valve (EBS) the cab
G 14.F Relay valve, 025 Installation only if drum brake fitted
027
G 50.F Compressed air reservoir 041 Installation for vehicle with spare wheel
wheelbase R 2980
(regeneration) not if 2-chamber air dryer 042 Installation for vehicle without spare
is fitted wheel wheelbase R 2980
G 53.3 Filling valve 045 = with trailer brake
G 55.F Pressure switch, pneumatic 050 = PA lines for compressed air reservoir,
5.8 - 0.4 bar
2.04 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0754, as of: 03.02, Sheet 2, for trucks/tippers, model H 36, 32./35.xxx FFD/FFDK, with air dryer, with leaf suspension, with and without trailer brake.
RA - P 85 2.05 - 1
KEY
Keys to installation diagram, 81.99133.0755, for trucks/tippers, model H25, 26./33.xxx FDR/FDRK
Note:
cylinder
020
the cab
(ECAM) 024 Distributor
G 50.F Compressed air reservoir 025 Installation only if drum brake fitted
5.8 - 0.4 bar 027
G 67.F Pressure control module tipper wheelbase R3600, R3900
Supplement 1 (with trailer) truck wheelbase R3900
G 17.F Trailer control module 036 Additional compressed air reservoir for
G 19.4 Coupling head, 2-line, brake, yellow truck wheelbase R3600
RA - P 85 2.06 -1
Brake system installation diagram no.: 81.99133.0755, as of: 02.02, Sheet 1, for trucks/tippers, model H 25, 26/33.xxx FD/FDK, with ECAM system, with leaf suspension, with and without trailer brake.
2.05 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0755, for trucks/tippers, model H25, 26./33.xxx FDR/FDRK
Note:
cylinder
5 connections
020
G 7.301 Service brake valve (EBS) the cab
G 14.F Relay valve, 025 Installation only if drum brake fitted
027
G 50. 40 Compressed air reservoir, 4l, 12.5 bar 034 Additional compressed air reservoir for
(regeneration) not if 2-chamber air dryer tipper wheelbase R3600, R3900
is fitted 035 Additional compressed air reservoir for
G 53.3 Filling valve truck wheelbase R3900
5.8 - 0.4 bar 037 Additional compressed air reservoir for
G 61.200 Solenoid valve, air in, NW 2.2 depending on wheelbase
2.06 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0755, as of: 02.02, Sheet 2, for trucks/tippers, model H 25, 26./33.xxx FD/FDK, with air dryer, with leaf suspension, with and without trailer brake.
RA - P 85 2.07 - 1
KEY
Keys to installation diagram, 81.99133.0756, for trucks/semitrailers, model H25, 26./33.xxx FDR/FDRS
Note:
cylinder
020
the cab
(ECAM) 024 Distributor
G 50.F Compressed air reservoir 025 Installation only if drum brake fitted
5.8 - 0.4 bar 027
G 67.F Pressure control module truck wheelbase R3200
semitrailer wheelbase R3600, R3900
RA - P 85 2.08 -1
Brake system installation diagram no.: 81.99133.0756, as of: 02.02, Sheet 1, for trucks/semitrailers, model H 25, 26./33.xxx FD/FDS, with ECAM system, with leaf suspension, with and without trailer brake.
2.07 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0756, for trucks/semitrailers, model H25, 26./33.xxx FDR/FDRS
Note:
G 1.2 Air compressor, optional one/two-cylinder 008
5 connections
020
G 7.301 Service brake valve (EBS) 022 See installation drawing, installation in
the cab
024 Distributor
G 14.F Relay valve,
G 23.201 Double check valve connections on battery box
G 25.F Air dryer with pressure regulator 027
(regeneration) not if 2-chamber air dryer 038 Additional compressed air reservoir for
is fitted truck wheelbase R3200
G 53.3 Filling valve 039 Additional compressed air reservoir for
semitrailer wheelbase R3600, R3900
5.8 - 0.4 bar 050 = PA lines for compressed air reservoir,
2.08 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0756, as of: 02.02, Sheet 2, for trucks/semitrailers, model H 25, 26./33.xxx FDR/FDRS, with air dryer, with leaf suspension, with and without trailer brake.
RA - P 85 2.09 - 1
KEY
Keys to installation diagram, 81.99133.0757, for trucks/tippers, model H40, 32./35.xxx FFDLK/FGK
Note:
G 5.67 Pressure limiting valve 20/3.5 +0.2 bar 012 Coupling head, reservoir (red)
G 14.F Relay valve,
the cab
024 Distributor
(ECAM)
5.8 - 0.4 bar
3/2-way valve (auxiliary brake system) 041 Additional Compressed air reservoir for
wheelbase 2980 with spare wheel
Supplement 1 (with trailer) wheelbase 2980 without spare wheel
G 17.F Trailer control module 045 = with trailer brake
G 19.3 Coupling head, 2-line reservoir, red 050 = PA lines for compressed air reservoir,
RA - P 85 2.10 -1
Brake system installation diagram no.: 81.99133.0757, as of: 04.02, Sheet 1, for trucks/tippers, model H 40, 32./35.xxx FFD/FFDL, with ECAM system, with air suspension, with and without trailer brake.
2.09 - 2 RA - P 85
KEY
with air dryer and air suspension, sheet 2, as of: 04. 02,
Note:
5 connections
the cab
024 Distributor
G 14.F Relay valve,
G 22.200 Quick-release valve connections on battery box
G 25.F Air dryer with pressure regulator 028 See installation drawing, brake hoses
041 Additional Compressed air reservoir for
G 50. 40 Compressed air reservoir, 4l, 12.5 bar wheelbase 2980 with spare wheel
(regeneration) not if 2-chamber air dryer
wheelbase 2980 without spare wheel
G 55.200 Pressure sensor, NC contact, depending on wheelbase
5.8 - 0.4 bar
2.10 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0757, as of: 04.02, Sheet 2, for trucks/tippers, model H 40, 32./35.xxx FFD/FFDL, with air dryer, with air suspension, with and without trailer brake.
RA - P 85 2.11 - 1
KEY
Note:
G 5.67 Pressure limiting valve 20/3.5 +0.2 bar 012 Coupling head, reservoir (red)
G 14.F Relay valve,
the cab
024 Distributor
(ECAM)
5.8 - 0.4 bar
3/2-way valve (auxiliary brake system) 041 Additional Compressed air reservoir for
wheelbase 2980 with spare wheel
Supplement 1 (with trailer) wheelbase 2980 without spare wheel
G 17.F Trailer control module 045 = with trailer brake
G 19.3 Coupling head, 2-line reservoir, red 050 = PA lines for compressed air reservoir,
RA - P 85 2.12 -1
Brake system installation diagram no.: 81.99133.0758, as of: 04.02, Sheet 1, for trucks/tippers, model H 40, 32./35.xxx FFD/FFDL/FG, with ECAM system, with air suspension, with and without trailer brake.
2.11 - 2 RA - P 85
KEY
with air dryer and air suspension, sheet 2, as of: 04. 02,
Note:
5 connections
the cab
024 Distributor
G 14.F Relay valve,
G 22.200 Quick-release valve connections on battery box
G 25.F Air dryer with pressure regulator 028 See installation drawing, brake hoses
041 Additional Compressed air reservoir for
G 50. 40 Compressed air reservoir, 4l, 12.5 bar wheelbase 2980 with spare wheel
wheelbase 2980 without spare wheel
G 55.200 Pressure sensor, NC contact, depending on wheelbase
5.8 - 0.4 bar
2.12 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0758, as of: 04.02, Sheet 2, for trucks/tippers, model H 40, 32./35.xxx FFD/FFDL, with air dryer, with air suspension, with and without trailer brake.
RA - P 85 2.13 - 1
KEY
Note:
the cab
(ECAM)
G 55,300 Pressure sensor, NC contact, 030 See installation drawing, large battery
5.8 - 0.4 bar box
box
RA - P 85 2.14 -1
Brake system installation diagram no.: 81.99133.0768, as of: 10.02, Sheet 1, for trucks/semitrailers, model H 23, 26.xxx FVL/FVLL, with ECAM system, with air suspension, with lifting leading axle, with and without trailer brake.
2.13 - 2 RA - P 85
KEY
Keys to installation diagram, 81.99133.0768, for trucks/semitrailers, model H23 , 26.xxx FVL
Note:

cylinder
5 connections
G 5.1 Pressure limiting valve 10/0.3 -0.2 bar
G 5.200 Pressure limiting valve, 8.5 - 0.4 bar G 50. 40 Compressed air reservoir, 4l, 12.5 bar
G 5.201 Pressure limiting valve, 10 0.3 bar G 51.3 Drain valve with pin, without ring
G 7.301 Service brake valve, EBS Supplements without G no. (device no.)
008 Line to air suspension (see installation
G 11.F Combination brake cylinder diagram, air suspension)
G 14.66 Relay valve with lead, 0.4 bar, 012 Coupling head, reservoir (red)
connection 3 = M 22 x 1.5 013 Coupling head, brake (yellow)
G 21.F Double check valve, 020 See installation diagram, air suspension
G 23.F Double check valve installation diagrams)
the cab
G 27.63 Silencer (M 22 x 1.5) 023 Distributor, pedal plate
025
is fitted 026
G 50. 305 Compressed air reservoir (circuit, service 027
G 55.300 Pressure sensor, NC contact, 045 = with trailer brake
5.8 - 0.4 bar
2.14 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0768, as of: 10.02, Sheet 2, for trucks/semitrailers, model H 23, 26.xxx FVL/FVLL, with air dryer, with air suspension, with lifting leading axle, with and without trailer brake.
RA - P 85 2.15 - 1
KEY
Note:
the cab
(ECAM)
5.8 - 0.4 bar box
box
RA - P 85 2.16 -1
Brake system installation diagram no.: 81.99133.0769, as of: 10.02, Sheet 1, for trucks/semitrailers, model H 23, 26.xxx FVL/FVLL, with ECAM system, with air suspension, with lifting leading axle, with and without trailer brake.
2.15 - 2 RA - P 85
KEY
Note:

cylinder
5 connections
G 5.1 Pressure limiting valve 10/0.3 -0.2 bar
G 5.200 Pressure limiting valve, 8.5 - 0.4 bar G 50. 40 Compressed air reservoir, 4l, 12.5 bar
G 5.201 Pressure limiting valve, 10 0.3 bar G 51.3 Drain valve with pin, without ring
G 7.301 Service brake valve, EBS Supplements without G no. (device no.)
G 10.F Diaphragm brake cylinder 008 Line to air suspension (see installation
G 11.F Combination brake cylinder diagram, air suspension)
G 14.66 Relay valve with lead, 0.4 bar, 012 Coupling head, reservoir (red)
connection 3 = M 22 x 1.5
G 14.300 PA relay valve 014 Dummy plug without coupling head
G 21.F Double check valve, 020 See installation diagram, air suspension
G 23.F Double check valve installation diagrams)
G 25.2F Air dryer with pressure regulator 022 See installation drawing, installation in
the cab
G 27.63 Silencer (M 22 x 1.5) 023 Distributor, pedal plate
025
is fitted 026
G 50. 305 Compressed air reservoir (circuit, service 027
G 55.300 Pressure sensor, NC contact, 045 = with trailer brake
5.8 - 0.4 bar
2.16 - 2 RA - P 85
Brake system installation diagram no.: 81.99133.0769, as of: 10.02, Sheet 2, for trucks/semitrailers, model H 23, 26.xxx FVL/FVLL, with air dryer, with air suspension, with lifting leading axle, with and without trailer brake.
RA - P 85 2.17 - 1
FUNCTION DIAGRAMS
Brake Function Diagrams
10.2002
RA - P 85 2.20 -1
OVERVIEW, FUNCTION DIAGRAMS, 2-AXLE TRUCKS
Function diagrams
Overview for
2-axle trucks, vehicles with leaf and air suspension
18 t gross vehicle weight
Pneumatically braked front and rear axle
With LUCAS - D-ELSA disc brakes on front and rear axle
Vehicle Model no. Function Date Trailer brake Air Special Page Notes
models diagram connection suspension version
81.99131.
18.xxx H 05, H 07 Truck/

0650 12.00 X X 2.11-1
FL/FLL H 09, H 14 tipper/
semi-
trailer
H05, H 06, Truck/

18.xxx 0651 12.00 X X 2.11-2
H07, H 09, tipper/
FL/HLL
H12, H 14, semi-
H 61 trailer
H 02, Truck
18.xxx F 0729 02.00 X X 2.13-1
H 02, Truck
18.xxx F 0730 02.00 X X 2.13-2
H 02, Truck
18.xxx F 0743 10.01 X X 2.15-1
H 02, Truck
18.xxx F 0744 10.01 X X 2.15-2
H 02, Truck/
18.xxx 0778 12.01 X X 2.17-1
H 51, tipper/
F/FA
semi-
trailer
H 02, Truck/
18.xxx 0779 12.01 X X 2.17-2
H 51, tipper
F/FA
RA - P 85 2.20 -3
KEY
Keys to function diagram, 81.99131.0650, as of: 12. 00

Note:
Key (without trailer, without air springs)
G 1.1 Air compressor, one-cylinder, 361 cc, G 50.300 Compressed air reservoir
for vehicles with leaf suspension 40 L EC (310 x 605) 12.5 bar
G 1.2 Air compressor, two-cylinder, 585 cc, G 51.3 Drain valve with pin, without ring
for vehicles with air suspension
G 54.X Test connections
G 7.302 Service brake valve,
G 55.300 Pressure switch, pneumatic,
NC contact, 5.8 - 0.4 bar (parking brake
G 8.205 Parking brake valve (parking brake system)
system) with test valve
G 10.300 Diaphragm brake cylinder, right,
G 57.2 Pressure gauge (electrical)
type 24", for D-ELSA disc brake
(circuit I and circuit II) see elec. system
G 10.301 Diaphragm brake cylinder, left,
G 57.300 Pressure sensor, see elec. system
type 24" for D-ELSA disc brake
G 11.300 Combination brake cylinder, right,
type 20/24", piston rod 20 mm,
for D-ELSA disc brake G 67.304 Pressure control module, 1-channel
G 11.301 Combination brake cylinder, left, G 67.305 Pressure control module, 2-channel
type 20/24" piston rod 20 mm,
for D-ELSA disc brake Supplements without G no. (device no.)
G 14.300 PA relay valve, for parking brake system
only 001
G 25.300 Electronically controlled air management 002 Check lamp, reservoir, circuit 1 & 2
(ECAM), 12.5 bar (with changeover 003 Check lamp, parking brake system
cartridge, without heater)
Pressures in bar: Normal mode 004 Pressure gauge, reservoir pressure
Deactivation pressure 12.5 0.3 circuit 1 and circuit 2
Operating range 2.0 - 0.2 005 Automatic adjuster
Circuit pressure c. 21 12.5 0.3
Circuit pressure c. 22 12.5 0.3 006 Mechanical emergency release
Circuit pressure c. 23/23.1 8.5 - 1.3 device
Circuit pressure c. 24 10.0 + 0.5/-2 007 Line to the auxiliary consumers
Dyn. circuit protection 008 Line to air suspension
pressure 6.5 + 1.0 009
G27.46 Breather element (snap connection/ 010
hose)
011 Electrical activation, auxiliary brake
G27.66 Silencer for air dryer with snap system (engine stop)
connection
012
013
014
2.20 - 4 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0650, as of: 12. 00, Heavy Range Trucks, model 18.XXXFL/FLL, version without trailer brake connection, D - ELSA II disc brake on front and driven axle.
RA - P 85 2.21 - 1
KEY

Note:

G 1.1 Air compressor, one-cylinder, 361 cc, G 55.300 Pressure switch, pneumatic,
for vehicles with leaf suspension NC contact, 5.8 - 0.4 bar (parking brake
G 1.2 Air compressor, two-cylinder, 585 cc, system)
for vehicles with air suspension G 56.2 Compressed air cylinder for exhaust flap
G 5.121 Safety valve, 17 + 2 bar G 57.2 Pressure gauge (electrical)
G 7.302 Service brake valve, (circuit I and circuit II) see elec. system
2-circuit tandem valve G 57.300 Pressure sensor, see elec. system
G 8.205 Parking brake valve (parking brake G 61.200 Solenoid valve, air in, NW 2.2
system) with test valve 3/2-way valve (auxiliary brake system)
G 10.300 Diaphragm brake cylinder, right, G 67.304 Pressure control module, 1-channel
type 24", for D-ELSA disc brake G 67.305 Pressure control module, 2-channel
G 10.301 Diaphragm brake cylinder, left, Supplement 1 (with trailer)
G 11.300 Combination brake cylinder, right, G 17.301 Trailer control module, 2-line
type 20/24", piston rod 20 mm, G 19.3 Coupling head, 2-line
for D-ELSA disc brake with reversal protection
G 11.301 Combination brake cylinder, left, reservoir red (single) with closing
type 20/24" piston rod 20 mm, element
for D-ELSA disc brake G 19.4 Coupling head, 2-line
G 14.300 PA relay valve, for parking brake system with reversal protection
only brake yellow with closing element
G 25.300 Electronically controlled air management G 19.30 Dead coupling, 2-line
(ECAM), 12.5 bar (with changeover G 29. 3 Serpentine hose unions,
cartridge, without heater) reservoir/brake (black)
Pressures in bar: Normal mode
Deactivation pressure 12.5 0.3 Supplements without G no. (device no.)
Operating range 2.0 - 0.2 001
Circuit pressure c. 21 12.5 0.3 002 Check lamp, reservoir, circuit 1 and 2
Circuit pressure c. 23/23.1 8.5 - 1.3 003 Check lamp, parking brake system
Circuit pressure c. 24 10.0 + 0.5/-2 004 Pressure gauge, reservoir pressure,
Circuit pressure c. 25 12.5 0.3 circuit 1 and 2
Dyn. circuit protection 005 Automatic adjuster
pressure 6.5 + 1.0 006 Mechanical emergency release device
007 Line to the auxiliary consumers
G27.46 Breather element (snap connection/
hose) 008 Line to air suspension
009
G27.66 Silencer for air dryer with snap
connection 010
G 50.300 Compressed air reservoir system (engine stop)
40 L EC (310 x 605) 12.5 bar
G 51.3 Drain valve with pin, without ring 013 Coupling head, brake (yellow)
G 54.X Test connections 015
RA - P 85 2.22 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0651, as of: 12.00, Heavy Range trucks, model 18.XXX FL/FLL, version with trailer brake connection, D - ELSA disc brake on front and driven axle.
2.21 - 2 RA - P 85
KEY

Note:

2-circuit tandem valve G 61.200 Solenoid valve, air in, NW 2.2
G 8.205 Parking brake valve (parking brake 3/2-way valve (auxiliary brake system)
system) with test valve G 67.304 Pressure control module, 1-channel
type 24", for D-ELSA disc brake G 74.300 Position sensor
type 24" for D-ELSA disc brake Supplements without G no. (device no.)
G 11.315 Combination brake cylinder, left, 001
type 20/24", piston rod 20 mm, 002 Check lamp, reservoir, circuit 1 and 2
for D-ELSA disc brake
003 Check lamp, parking brake system
type 20/24", piston rod 20 mm, 004 Pressure gauge, reservoir pressure,
for D-ELSA disc brake circuit 1 and circuit 2
G 14.300 PA relay valve, for parking brake system 005 Automatic adjuster
only 006 Mechanical emergency release device
G 25.300 Electronically controlled air management 007 Line to the auxiliary consumers
(ECAM), 12.5 bar (with changeover 008 Line to air suspension
cartridge, without heater) 009
Pressures in bar: Normal mode 010
Deactivation pressure 12.5 0.3
Operating range 2.0 - 0.2
system (engine stop)
Circuit pressure c. 22 12.5 0.3 012 Coupling head, reservoir (red)
Circuit pressure c. 23/23.1 8.5 - 1.3 013 Coupling head, brake (yellow)
Circuit pressure c. 24 10.0 + 0.5/-2 014
Circuit pressure c. 25 12.5 0.3 015
Dyn. circuit protection
pressure 6.5 + 1.0

hose)
connection
G 50.300 Compressed air reservoir
40 L EC (310 x 605) 12.5 bar
2.22 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0729, as of: 02. 00, Heavy Range Trucks, model 18.XXX F, version without trailer brake connection, D - ELSA disc brake on front and driven axle.
RA - P 85 2.23 - 1
KEY

Note:
G 10.301 Diaphragm brake cylinder, left, Supplement 1 (with trailer)
G 11.315 Combination brake cylinder, left, G 17.301 Trailer control module, 2-line
G 11.316 Combination brake cylinder, right, reservoir red (single) with closing
type 20/24", piston rod 20 mm, element
Circuit pressure c. 24 10.0 + 0.5/-2 004 Pressure gauge, reservoir pressure,
Circuit pressure c. 25 12.5 0.3 circuit 1 and circuit 2
009
connection 010
40 L EC (310 x 605) 12.5 bar
G 54.X Test connections 015
RA - P 85 2.24 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0730, as of: 02.00, Heavy Range trucks, model 18.XXX F, version with trailer brake connection, D - ELSA disc brake on front and driven axle.
2.23 - 2 RA - P 85
KEY

Note:
G 5.67 Pressure limiting valve 20/3.5 +0.2 bar G 57.2 Pressure gauge (electrical)
G 5.121 Safety valve, 17 + 2 bar (circuit I and circuit II) see elec. system
G 7.302 Service brake valve, G 61.200 Solenoid valve, air in, NW 2.2
2-circuit tandem valve 3/2-way valve (auxiliary brake system)
G 8.205 Parking brake valve (parking brake G 67.304 Pressure control module, 1-channel
G 10.300 Diaphragm brake cylinder, right, G 74.300 Position sensor
G 10.301 Diaphragm brake cylinder, left, Supplements without G no. (device no.)
type 24" for D-ELSA disc brake 001
G 11.209 Combination brake cylinder, left, 002 Check lamp, reservoir, circuit 1 and 2
type 24/30", piston rod 75 mm 003 Check lamp, parking brake system
G 14.202 Overload protection relay 004 Pressure gauge, reservoir pressure,
G 25.300 Electronically controlled air management circuit 1 and circuit 2
(ECAM), 12.5 bar (with changeover 005 Automatic adjuster
006 Mechanical emergency release device
Operating range 2.0 - 0.2 008 Line to air suspension
Circuit pressure c. 23/23.1 8.5 - 1.3 011 Electrical activation, auxiliary brake
Circuit pressure c. 24 10.0 + 0.5/-2 system (engine stop)
pressure 6.5 + 1.0 013 Coupling head, brake (yellow)
014
G 27.46 Breather element (snap connection/ 015
hose)
G 27.65 Silencer for valves with snap connection
G 27.66 Silencer for air dryer with snap
connection
40 L EC (310 x 605) 12.5 bar
2.24 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0743, as of: 10. 01, Heavy Range Trucks, model 18.XXX F, version without trailer brake connection, D - ELSA disc brake on front axle and drum brake on driven axle.
RA - P 85 2.25 - 1
KEY

Note:

type 24", for D-ELSA disc brake Supplement 1 (with trailer)
type 24" for D-ELSA disc brake G 17.301 Trailer control module 2-line
G 11.209 Combination brake cylinder, left, G 19.3 Coupling head, 2-line
type 24/30", piston rod 75 mm with reversal protection
G 14.202 Overload protection relay reservoir red (single) with closing
element
G 25.300 Electronically controlled air management
(ECAM), 12.5 bar (with changeover G 19.4 Coupling head, 2-line
cartridge, without heater) with reversal protection
brake yellow with closing element
Deactivation pressure 12.5 0.3 G 19.30 Dead coupling, 2-line
Operating range 2.0 - 0.2 G 29. 3 Serpentine hose unions,
Circuit pressure c. 21 12.5 0.3 reservoir/brake (black)
Circuit pressure c. 23/23.1 8.5 - 1.3 Supplements without G no. (device no.)
Circuit pressure c. 24 10.0 +0.5/-2 001
pressure 6.5 + 1.0
004 Pressure gauge, reservoir pressure,
circuit 1 and circuit 2
hose) 005 Automatic adjuster
008 Line to air suspension
connection
009
010
40 L EC (310 x 605) 12.5 bar
G 51.3 Drain valve with pin, without ring system (engine stop)
G 53.3 Filling valve 012 Coupling head, reservoir (red)
G 54.X Test connections 013 Coupling head, brake (yellow)
014
015
RA - P 85 2.26 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0744, as of: 10.01, Heavy Range trucks, model 18.XXX F, version with trailer brake connection, D - ELSA disc brake on front axle and drum brake on driven axle.
2.25 - 2 RA - P 85
KEY

Note:

type 27", piston rod 37 mm, 75 stroke
G 11.209 Combination brake cylinder, left, Supplement 1 (with trailer)
type 24/30", piston rod 75 mm
G 17.301 Trailer control module 2-line
G 14.202 Overload protection relay
G 19.3 Coupling head, 2-line
with reversal protection
(ECAM), 12.5 bar (with changeover
reservoir red (single) with closing
element
Deactivation pressure 12.5 0.3 with reversal protection
Operating range 2.0 - 0.2 brake yellow with closing element
Circuit pressure c. 23/23.1 8.5 - 1.3 G 29. 3 Serpentine hose unions,
Circuit pressure c. 24 10.0 + 0.5/-2 reservoir/brake (black)
Circuit pressure c. 25 12.5 0.3 Supplements without G no. (device no.)
Dyn. circuit protection 001
pressure 6.5 + 1.0
002 Check lamp, reservoir, circuit 1 and 2
G 27.46 Breather element (snap connection/
hose) 004 Pressure gauge, reservoir pressure,
005 Automatic adjuster
G 27.66 Silencer for air dryer with snap 006 Mechanical emergency release device
connection
G 50.300 Compressed air reservoir, 40 L EC 008 Line to air suspension
12.5 bar (not all-wheel drive vehicles)
009
G 50.301 Compressed air reservoir, 30 L EC 010
12.5 bar (all-wheel drive vehicles)
G 50.302 Compressed air reservoir, 8 L EC system (engine stop)
12.5 bar (all-wheel drive vehicles) 012 Coupling head, reservoir (red)
015
2.26 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0778, as of: 12. 01, Heavy Range Trucks, model 18.XXX F/FA, version with trailer brake connection, drum brake on front and driven axle.
RA - P 85 2.27 - 1
KEY

Note:

G 10.31 Diaphragm brake cylinder, type 27", G 74.300 Position sensor
piston rod 37 mm
G 11.209 Combination brake cylinder, type 24/30", Supplements without G no. (device no.)
piston rod 75 mm 001
G 14.202 Overload protection relay 002 Check lamp, reservoir, circuit 1 and 2
G 25.300 Electronically controlled air management 003 Check lamp, parking brake system
(ECAM), 12.5 bar (with changeover 004 Pressure gauge, reservoir pressure,
cartridge, without heater) circuit 1 and circuit 2
Pressures in bar: Normal mode 005 Automatic adjuster
Circuit pressure c. 21 12.5 0.3 007 Line to the auxiliary consumers
Circuit pressure c. 22 12.5 0.3 008 Line to air suspension
Circuit pressure c. 23/23.1 8.5 - 1.3 009
pressure 6.5 + 1.0
G 27.46 Breather element (snap connection/ 013 Coupling head, brake (yellow)
hose) 014
G 27.65 Silencer for valves with snap connection 015
connection
G 50.300 Compressed air reservoir, 40 L EC
RA - P 85 2.28 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0779, as of: 12.01, Heavy Range trucks, model 18.XXX F/FA, version without trailer brake connection, drum brake on front and driven axle.
2.27 - 2 RA - P 85
Function diagrams
Overview for
- 3-axle trucks (FNL/FNLL, FVL/FVLL - Heavy Range TG-A)
- 24 to 26 t gross vehicle weight
- Pneumatically braked front, leading, trailing and rear axle
- MERITOR-D ELSA disc brakes on the front, leading, trailing and rear axle
Vehicle Model no. Function Trailer Air Special Remarks

models diagram Date brake suspension version Page
81.99131 connection
with with- with with-
out out
24./26.XXX H 16, H 17 0656 11. 00 X X 2.51-1 Truck/

HNL/HNLL H 19, H 20 semitrailer
H 27, H 31
H 44
26:XXX H 16, H 17 0657 11. 00 X X 2.51-2 Truck/
FNL/FNLL H 19, H 20 semitrailer
H 27, H 31
H 44
26:XXX H 23 0738 01.01 X X 2.53-1 Truck/
FVL/FVLL H 32 semitrailer
26:XXX H 23, 0739 09.00 X X 2.53-2 Truck/
FVL/FVLL
semitrailer
RA - P 85 2.50 -1
KEY

Note:
2. The key is split up into several sections. It comprises the basic version (without trailer, without air
suspension), the following supplementary keys: 1. With trailer; 2. With semitrailer; 3. With air springs;
and the supplements without G no. (device number)
G 1.1 Air compressor, one-cylinder, 361 cc, G 27.66 Silencer for air dryer with snap
for vehicles with leaf suspension connection
G 1.2 Air compressor, two-cylinder, 585 cc, G 50.300 Compressed air reservoir
for vehicles with air suspension 40 L EC (310 x 605) 12.5 bar
G 5.121 Safety valve, 17 + 2 bar G 50.301 Compressed air reservoir
30 L EC (310 x 462) 12.5 bar
2-circuit tandem valve G 51.3 Drain valve with pin, without ring
G 8.205 Parking brake valve (parking brake G 53.3 Filling valve
system) with test valve G 54.X Test connections
G 10.300 Diaphragm brake cylinder, right, G 55.300 Pressure switch, pneumatic,
type 24", for D-ELSA disc brake NC contact, 5.8 - 0.4 bar (parking brake
G 10.301 Diaphragm brake cylinder, left, system)
type 24" for D-ELSA disc brake G 56.2 Compressed air cylinder for exhaust flap
G 11.300 Combination brake cylinder, right, G 57.2 Pressure gauge (electrical)
type 20/24", piston rod 20 mm, (circuit I and circuit II) see elec. system
G 11.301 Combination brake cylinder, left,
type 20/24" piston rod 20 mm, G 61.200 Solenoid valve, air in, NW 2.2
for D-ELSA disc brake 3/2-way valve (auxiliary brake system)
G 67.305 Pressure control module, 2-channel
G 11.310 Combination brake cylinder, right, Supplements without G no. (device no.)
for D-ELSA disc brake 001
G 14.66 Relay valve (lead 0.4) 002 Check lamp, reservoir, circuit 1 and 2
connection 3 = M 22x1.5 003 Check lamp, parking brake system
G 14.300 PA relay valve, for parking brake system circuit 1 and circuit 2
only 005 Automatic adjuster
G 21.11 Double check valve, 006 Mechanical emergency release device
opening at low pressure 007 Line to the auxiliary consumers
009
010
Pressures in bar: Normal mode system (engine stop)
Deactivation pressure 12.5 0.3 012
Circuit pressure c. 23/23.1 8.5 - 1.3
Circuit pressure c. 24 10.0 +0.5/-2
pressure 6.5 + 1.0

hose)
G 27.63 Silencer
2.50 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0656, as of: 11. 00, Heavy Range Trucks, model 26.XXX FNL/FNLL, version without trailer brake connection, D - ELSA disc brake on front, trailing and driven axle.
RA - P 85 2.51 - 1
KEY

Note:
G 1.2 Air compressor, two-cylinder, 585 cc, G 51.3 Drain valve with pin, without ring
for vehicles with air suspension G 53.3 Filling valve
G 5.121 Safety valve, 17 + 2 bar G 54.X Test connections
G 7.302 Service brake valve, G 55.300 Pressure switch, pneumatic,
2-circuit tandem valve NC contact, 5.8 - 0.4 bar (parking brake
G 8.205 Parking brake valve (parking brake system)
system) with test valve G 56.2 Compressed air cylinder for exhaust flap
G 10.300 Diaphragm brake cylinder, right, G 57.2 Pressure gauge (electrical)
type 24", for D-ELSA disc brake (circuit I and circuit II) see elec. system
G 10.301 Diaphragm brake cylinder, left, G 57.300 Pressure sensor, see elec. system
type 24" for D-ELSA disc brake G 61.200 Solenoid valve, air in, NW 2.2
G 11.300 Combination brake cylinder, right, 3/2-way valve (auxiliary brake system)
type 20/24", piston rod 20 mm, G 67.304 Pressure control module, 1-channel
for D-ELSA disc brake G 17.301 Trailer control module 2-line
type 10/16", piston rod 20 mm, with reversal protection
for D-ELSA disc brake reservoir red (single) with closing
G 11.310 Combination brake cylinder, right, element
G 14.66 Relay valve (lead 0.4) brake yellow with closing element
connection 3 = M 22x1.5 G 19.30 Dead coupling, 2-line
G 14.300 PA relay valve, for parking brake system G 29. 3 Serpentine hose unions,
only reservoir/brake (black)
G 21.11 Double check valve,
opening at low pressure Supplements without G no. (device no.)
G 25.300 Electronically controlled air management 001
(ECAM), 12.5 bar (with changeover 002 Check lamp, reservoir, circuit 1 and 2
cartridge, without heater) 003 Check lamp, parking brake system
Pressures in bar: Normal mode 004 Pressure gauge, reservoir pressure,
Deactivation pressure 12.5 0.3 circuit 1 and circuit 2
Operating range 2.0 - 0.2 005 Automatic adjuster
Circuit pressure c. 21 12.5 0.3 006 Mechanical emergency release device
Circuit pressure c. 24 10.0 +0.5/-2 008 Line to air suspension
pressure 6.5 + 1.0 011 Electrical activation, auxiliary brake
G 27.46 Breather element (snap connection/ system (engine stop)
hose) 012 Coupling head, reservoir (red)
G 27.63 Silencer 013 Coupling head, brake (yellow)
G 27.66 Silencer for air dryer with snap 014
connection 015
40 L EC (310 x 605) 12.5 bar
RA - P 85 2.52 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0657, status as of: 11. 00, heavy range trucks, type 26.XXX FNL/FNLL, version with trailer brake connection, D - ELSA disc brake on front, trailing and driven axle.
2.51 - 2 RA - P 85
KEY

Note:
G 1.1 Air compressor, one-cylinder, 361 cc, G 50.300 Compressed air reservoir 40 L EC
for vehicles with leaf suspension 12.5 bar
G 1.2 Air compressor, two-cylinder, 585 cc, G 50.301 Compressed air reservoir, 30 L EC
for vehicles with air suspension 12.5 bar (for wheelbase 2600)
G 5.121 Safety valve, 17 + 2 bar G 50.305 Compressed air reservoir, 30 L EC
G 7.302 Service brake valve, 12.5 bar (for wheelbase =/<2600)
type 24", for D-ELSA disc brake NC contact, 5.8 - 0.4 bar parking brake
G 10.301 Diaphragm brake cylinder, left, system for trucks and buses
for D-ELSA disc brake G 57.300 Pressure sensor, see elec. system
G 11.301 Combination brake cylinder, left, G 61.200 Solenoid valve, air in, NW 2.2
type 20/24" piston rod 20 mm, 3/2-way valve (auxiliary brake system)
for D-ELSA disc brake Supplement 1 (with trailer)
G 11.318 Combination brake cylinder, right, G 17.301 Trailer control module 2-line
with reversal protection reservoir red
G 14.66 Relay valve (lead 0.4) (single) with closing element
connection 3 = M 22x1.5
G 19.4 Coupling head, 2-line with reversal
G 14.300 PA relay valve, for parking brake system protection brake yellow with closing
only element
G 21.11 Double check valve, G 19.30 Dead coupling, 2-line
G 24.9 Vent valve, pneumatically controlled reservoir/brake (black)
(Europe valve)
(ECAM), 12.5 bar (with changeover 001
cartridge, without heater) 002 Check lamp, reservoir, circuit 1 and 2
Pressures in bar: Normal mode 003 Check lamp, parking brake system
Deactivation pressure 12.5 0.3 004 Pressure gauge, reservoir pressure,
Operating range 2.0 - 0.2 circuit 1 and circuit 2
Circuit pressure c. 21 12.5 0.3 005 Automatic adjuster
Circuit pressure c. 22 12.5 0.3 006 Mechanical emergency release device
Circuit pressure c. 23/23.1 8.5 - 1.3 007 Line to the auxiliary consumers
Circuit pressure c. 24 10.0 +0.5/-2 008 Line to air suspension
pressure 6.5 + 1.0 010
G 27.46 Breather element (snap connection/ system (engine stop)
hose) 012 Coupling head, reservoir (red)
G 27.63 Silencer 013 Coupling head, brake (yellow)
connection 015
2.52 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0738, as of: 01. 01, Heavy Range Trucks, model 26.XXX FVL, version with trailer brake connection, D - ELSA disc brake on front, leading and driven axle.
RA - P 85 2.53 - 1
KEY

Note:

G 1.1 Air compressor, one-cylinder, 361 cc, G 27.66 Silencer for air dryer with snap
for vehicles with leaf suspension connection
G 1.2 Air compressor, two-cylinder, 585 cc, G 50.300 Compressed air reservoir, 40 L EC
for vehicles with air suspension 12.5 bar
G 5.121 Safety valve, 17 + 2 bar G 50.301 Compressed air reservoir, 30 L EC
G 7.302 Service brake valve, 12.5 bar
type 24", for D-ELSA disc brake NC contact, 5.8 - 0.4 bar (parking brake
G 10.301 Diaphragm brake cylinder, left, system)
type 20/24" piston rod 20 mm, G 61.200 Solenoid valve, air in, NW 2.2
for D-ELSA disc brake 3/2-way valve (auxiliary brake system)
type 10/16", piston rod 20 mm, 001
for D-ELSA disc brake 002 Check lamp, reservoir, circuit 1 and 2
G 14.66 Relay valve (lead 0.4)
connection 3 = M 22x1.5
G 14.300 PA relay valve, for parking brake system 004 Pressure gauge, reservoir pressure,
only circuit 1 and circuit 2
G 21.11 Double check valve, 005 Automatic adjuster
opening at low pressure 006 Mechanical emergency release device
G 24.9 Vent valve, pneumatically controlled 007 Line to the auxiliary consumers
(Europe valve) 008 Line to air suspension
G 25.300 Electronically controlled air management 009
Pressures in bar: Normal mode 011 Electrical activation, auxiliary brake
Deactivation pressure 12.5 0.3 system (engine stop)
Operating range 2.0 - 0.2 012 Coupling head, reservoir (red)
Circuit pressure c. 21 12.5 0.3 013 Coupling head, brake (yellow)
015
pressure 6.5 + 1.0
hose)
G 27.63 Silencer
RA - P 85 2.54 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0739, as of: 09.00, Heavy Range trucks, model 26.XXX FVL, version without trailer brake connection, D - ELSA disc brake on front, leading and driven axle.
2.53 - 2 RA - P 85
Continued
Vehicle Model no. Function Trailer Air Special Remarks

models diagram Date brake suspension version Page
81.99131 connection
out out
26./33./38./ H25, H26 0785 12.01 X X Front axle/ 3.21-1 Truck/

41.XXX H28, H55 rear axle tipper/
FD/FDA H72 drum brake semitrailer
26./33./38./ H25, H26 0786 12.01 X X Front axle/ 3.21-2 Truck/
41.XXX H28, H55 rear axle tipper/
FD/FDA H72 drum brake semitrailer
26./33.XXX H 25 0787 10.01 X X Front axle 3.23-1 Truck/
DF H 26 D-ELSA, tipper/
H 28 rear axle semitrailer
drum brake
26./33.XXX H 25 0788 10.01 X X Front axle 3.23-2 Truck/
DF H 26 D-ELSA, tipper/
H 28 rear axle semitrailer
drum brake
3.10 - 2 RA - P 85
KEY

Note:
suspension), the additional keys: 1. With trailer; 2. With semitrailer; 3. With air springs; and the
supplements without G no. (device number
G 7.302 Service brake valve, 2-circuit, tandem G 61.200 Solenoid valve, air in, NW 2.2
valve 3/2-way valve (auxiliary brake system)
system) G 67.305 Pressure control module, 2-channel
with test valve G 74.300 Position sensor
G 10.300 Diaphragm brake cylinder, right,
type 24" for D-ELSA disc brake G 17.301 Trailer control module 2-line
G 11.209 Combination brake cylinder, G 19.3 Coupling head, 2-line
G 11.220 Combination brake cylinder, right, reservoir red (single) with closing
type 24/30", piston rod 200 mm element
G 14.202 Overload protection relay brake yellow with closing element
Pressures in bar: Normal mode Supplements without G no. (device no.)
Circuit pressure c. 23/23.1 8.5 - 1.3 004 Pressure gauge, reservoir pressure,
Circuit pressure c. 24 10.0 +0.5/-2 circuit 1 and circuit 2
Dyn. circuit protection 006 Mechanical emergency release device
pressure 6.5 + 1.0 007 Line to the auxiliary consumers
009
hose)
010
G 27.65 Silencer for valves with snap connection 011 Electrical activation, auxiliary brake
G 27.66 Silencer for air dryer with snap system (engine stop)
connection 012
G 50.300 Compressed air reservoir 013
40 L EC (310 x 605) 12.5 bar 014
30 L EC (310 x 462) 12.5 bar
3.10 - 4 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0754, as of: 10.01, Heavy Range trucks, model 26./33.XXX DF, version with trailer brake connection, D - ELSA disc brake on front axle and drum brake on driven axles.
RA - P 85 3.11 - 1
Function diagrams
Overview for
- 3-axle trucks (FNL/FNLL Heavy Range, FVL/FVLL - Heavy Range TG-A)
- Disc brakes/drum brakes on the front, leading, trailing and rear axle
- Drum brakes on the front, leading, trailing and rear axle
Vehicle Model no. Function Trailer brake Air Special Remarks

models diagram Date connection suspension version Page
81.99131 with with- with with-
out out
26./33.XXX H 25 Front axle

0754 10.01 X X 3.11-1 Truck/
DF H 26 D-ELSA,
tipper/
H 28 rear axle
semitrailer
drum brake
0755 10.01 X X 3.11-2 Truck/
DF H 26 D-ELSA,
tipper/
rear axle
semitrailer
drum brake
26./33.XXX H 25 0756 03.01 X X Front axle/ 3.13-1 Truck/
DF H 26 rear axle tipper/
H 28 D-ELSA semitrailer
DF H 26 rear axle tipper/
D-ELSA semitrailer
DFL rear axle tipper/
D-ELSA semitrailer
D-ELSA semitrailer
D-ELSA semitrailer
0767 10 01 X X 3.17-2 Truck/
DFL D-ELSA,
tipper/
rear axle
semitrailer
drum brake
26./33.XXX H25, H26 0780 12.01 X X Front axle/ 3.19-1 Truck/
FD/FDA H28, H55 rear axle tipper/
H72 drum brake semitrailer
26./33.XXX H 25, 0781 12. 01 X X Front axle/ 3.19-2 Truck/
FD/FDA H 26, rear axle tipper/
H 55, drum brake semitrailer
RA - P 85 3.10 -1
KEY

Note:
G 1.1 Air compressor, one-cylinder, 361 cc, G 51.3 Drain valve with pin, without ring
for vehicles with leaf suspension
G 1.2 Air compressor, two-cylinder, 585 cc,
for vehicles with air suspension G 54.X Test connections
G 5.67 Pressure limiting valve 20/3.5 +0.2 bar G 55.300 Pressure switch, pneumatic,
G 5.121 Safety valve, 17 + 2 bar NC contact, 5.8 - 0.4 bar (parking brake
system)
G 7.302 Service brake valve, 2-circuit, tandem
valve G 56.2 Compressed air cylinder for exhaust flap
G 8.205 Parking brake valve (parking brake G 57.2 Pressure gauge (electrical)
system) with test valve (circuit I and circuit II) see elec. system
G 10.300 Diaphragm brake cylinder, right, G 61.200 Solenoid valve, air in, NW 2.2
type 24", for D-ELSA disc brake 3/2-way valve (auxiliary brake system)
G 10.301 Diaphragm brake cylinder, left, G 67.304 Pressure control module, 1-channel
type 24" for D-ELSA disc brake G 67.305 Pressure control module, 2-channel
G 11.209 Combination brake cylinder, G 74.300 Position sensor
type 24/30", piston rod 200 mm 001
G 11.221 Combination brake cylinder, left, 002 Check lamp, reservoir, circuit 1 and 2
type 24/30", piston rod 200 mm 003 Check lamp, parking brake system
cartridge, without heater) 005 Automatic adjuster
Pressures in bar: Normal mode 006 Mechanical emergency release device
Deactivation pressure 12.5 0.3 007 Line to the auxiliary consumers
Circuit pressure c. 24 10.0 +0.5/-2 011 Electrical activation, auxiliary brake
Circuit pressure c. 25 12.5 0.3 system (engine stop)
Dyn. circuit protection 012 Coupling head, reservoir (red)
hose) 015
connection
40 L EC (310 x 605) 12.5 bar
30 L EC (310 x 462) 12.5 bar
RA - P 85 3.12 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0755, as of: 10.01, Heavy Range trucks, model 26./33.XXX DF, version without trailer brake connection, D - ELSA disc brake on front axle and drum brake on driven axles.
3.11 - 2 RA - P 85
KEY

Note:

type 24" for D-ELSA disc brake Supplement 1 (with trailer)
type 20/24", piston rod 20 mm, G 17.301 Trailer control module 2-line
G 11.301 Combination brake cylinder, left, with reversal protection reservoir red
type 20/24" piston rod 20 mm, (single) with closing element
Pressures in bar: Normal mode Supplements without G no. (device no.)
Circuit pressure c. 22 12.5 0.3 003 Check lamp, parking brake system
pressure 6.5 + 1.0
G27.46 Breather element (snap connection/ 008 Line to air suspension
hose) 009
G27.66 Silencer for air dryer with snap 010
connection 011 Electrical activation, auxiliary brake
40 L EC (310 x 605) 12.5 bar 012 Coupling head, reservoir (red)
G 50.301 Compressed air reservoir 013 Coupling head, brake (yellow)
30 L EC (310 x 462) 12.5 bar 014
G 51.3 Drain valve with pin, without ring 015
3.12 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0756, as of: 03.01, Heavy Range trucks, model 26./33.XXX DF, version with trailer brake connection, D - ELSA disc brake on front and driven axles.
RA - P 85 3.13 - 1
KEY

Note:

for vehicles with leaf suspension G 53.3 Filling valve
G 1.2 Air compressor, two-cylinder, 585 cc, G 54.X Test connections
for vehicles with air suspension G 55.300 Pressure switch, pneumatic,
G 7.302 Service brake valve, system)
2-circuit tandem valve G 56.2 Compressed air cylinder for exhaust flap
G 11.300 Combination brake cylinder, right, G 74.300 Position sensor
type 20/24" piston rod 20 mm, 002 Check lamp, reservoir, circuit 1 and 2
only 004 Pressure gauge, reservoir pressure,
cartridge, without heater) 006 Mechanical emergency release device
Pressures in bar: Normal mode 007 Line to the auxiliary consumers
Deactivation pressure 12.5 0.3 008 Line to air suspension
Circuit pressure c. 22 12.5 0.3 011 Electrical activation, auxiliary brake
Circuit pressure c. 23/23.1 8.5 - 1.3 system (engine stop)
Circuit pressure c. 24 10.0 +0.5/-2 012 Coupling head, reservoir (red)
pressure 6.5 + 1.0 014
015
hose)
connection
40 L EC (310 x 605) 12.5 bar
30 L EC (310 x 462) 12.5 bar
RA - P 85 3.14 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0757, as of: 03.01, Heavy Range trucks, model 26./33.XXX DF, version without trailer brake connection, D - ELSA disc brake on front and driven axles.
3.13 - 2 RA - P 85
KEY

Note:

G 10.300 Diaphragm brake cylinder, right, G 57.300 Pressure sensor, see elec. system
G 11.301 Combination brake cylinder, left, Supplement 1 (with trailer)
(single) with closing element
G 14.300 PA relay valve, for parking brake system brake yellow with closing element
only
Operating range 2.0 - 0.2 002 Check lamp, reservoir, circuit 1 and 2
Circuit pressure c. 22 12.5 0.3 004 Pressure gauge, reservoir pressure,
Circuit pressure c. 23/23.1 8.5 - 1.3 circuit 1 and circuit 2
pressure 6.5 + 1.0 007 Line to the auxiliary consumers
G 27.46 Breather element (snap connection/ 008 Line to air suspension
hose) 009
30 L EC (310 x 462) 12.5 bar
014
015
3.14 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0764, as of: 03.01, Heavy Range trucks, model 26./33.XXX DFL, version with trailer brake connection, D - ELSA disc brake on front and driven axles.
RA - P 85 3.15 - 1
KEY

Note:

G 10.300 Diaphragm brake cylinder, right, G 57.300 Pressure sensor, see elec. system
type 24", for D-ELSA disc brake G 61.200 Solenoid valve, air in, NW 2.2
G 10.301 Diaphragm brake cylinder, left, 3/2-way valve (auxiliary brake system)
G 11.300 Combination brake cylinder, right, G 67.305 Pressure control module, 2-channel
type 20/24" piston rod 20 mm, 002 Check lamp, reservoir, circuit 1 and 2
for D-ELSA disc brake 003 Check lamp, parking brake system
G 11.319 Combination brake cylinder, right, 004 Pressure gauge, reservoir pressure,
type 20/24", piston rod 20 mm circuit 1 and circuit 2
G 11.320 Combination brake cylinder, left, 005 Automatic adjuster
only 007 Line to the auxiliary consumers
G 25.300 Electronically controlled air management 008 Line to air suspension
Pressures in bar: Normal mode 011 Electrical activation, auxiliary brake
Deactivation pressure 12.5 0.3 system (engine stop)
Operating range 2.0 - 0.2 012 Coupling head, reservoir (red)
pressure 6.5 + 1.0
hose)
connection
40 L EC (310 x 605) 12.5 bar
30 L EC (310 x 462) 12.5 bar
RA - P 85 3.16 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0765, as of: 03.01, Heavy Range trucks, model 26./33.XXX DFL, version with trailer brake connection, D - ELSA disc brake on front and driven axles.
3.15 - 2 RA - P 85
KEY

Note:

G 5.67 Pressure limiting valve 20/3.5 +0.2 bar NC contact, 5.8 - 0.4 bar (parking brake
G 5.121 Safety valve, 17 + 2 bar system)
G 7.302 Service brake valve, G 56.2 Compressed air cylinder for exhaust flap
2-circuit tandem valve G 57.2 Pressure gauge (electrical)
G 8.205 Parking brake valve (parking brake (circuit I and circuit II) see elec. system
system) with test valve G 57.300 Pressure sensor, see elec. system
G 11.209 Combination brake cylinder,
type 24/30", piston rod 75 mm Supplement 1 (with trailer)
type 24/30", piston rod 200 mm G 17.301 Trailer control module 2-line
G 14.202 Overload protection relay element
G 25.300 Electronically controlled air management G 19.4 Coupling head, 2-line
(ECAM), 12.5 bar (with changeover with reversal protection
cartridge, without heater) brake yellow with closing element
Pressures in bar: Normal mode G 19.30 Dead coupling, 2-line
Deactivation pressure 12.5 0.3 G 29. 3 Serpentine hose unions,
Operating range 2.0 - 0.2 reservoir/brake (black)
Circuit pressure c. 24 10.0 +0.5/-2 002 Check lamp, reservoir, circuit 1 and 2
Dyn. circuit protection 004 Pressure gauge, reservoir pressure,
pressure 6.5 + 1.0 circuit 1 and circuit 2
hose) 006 Mechanical emergency release device
009
connection
010
40 L EC (310 x 605) 12.5 bar 011 Electrical activation, auxiliary brake
014
015
3.16 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0766, as of: 10. .01, Heavy Range trucks, model 26./33.XXX DFL, version with trailer brake connection, D - ELSA disc brake on front axle and drum brake on driven axles.
RA - P 85 3.17 - 1
KEY

Note:

type 24/30", piston rod 75 mm Supplements without G no. (device no.)
G 11.220 Combination brake cylinder, right, 001
type 24/30", piston rod 200 mm 002 Check lamp, reservoir, circuit 1 and 2
G 11.221 Combination brake cylinder, left, 003 Check lamp, parking brake system
type 24/30", piston rod 200 mm 004 Pressure gauge, reservoir pressure,
G 14.202 Overload protection relay circuit 1 and circuit 2
G 25.300 Electronically controlled air management 005 Automatic adjuster
(ECAM), 12.5 bar (with changeover 006 Mechanical emergency release device
pressure 6.5 + 1.0 015
hose)
connection
40 L EC (310 x 605) 12.5 bar
30 L EC (310 x 462) 12.5 bar
RA - P 85 3.18 -1
FUNCTION DIAGRAM
Brake system function diagram no. 81.99131.0767, as of: 10.01, Heavy Range trucks, model 26./33.XXX DFL, version without trailer brake connection, D - ELSA disc brake on front axle and drum brake on driven axles.
3.17 - 2 RA - P 85
KEY

Note:

system) G 61.200 Solenoid valve, air in, NW 2.2
with test valve 3/2-way valve (auxiliary brake system)
G 10.31 Diaphragm brake cylinder, G 67.304 Pressure control module, 1-channel
type 27", piston rod 37 mm G 67.305 Pressure control module, 2-channel
G 11.209 Combination brake cylinder, G 74.300 Position sensor
G 11.220 Combination brake cylinder, right, Supplement 1 (with trailer)
G 11.221 Combination brake cylinder, left, G 17.301 Trailer control module 2-line
type 24/30", piston rod 200 mm G 19.3 Coupling head, 2-line
G 14.202 Overload protection relay with reversal protection
element
cartridge, without heater) G 19.4 Coupling head, 2-line
Operating range 2.0 - 0.2 G 19.30 Dead coupling, 2-line
Circuit pressure c. 21 12.5 0.3 G 29. 3 Serpentine hose unions,
Circuit pressure c. 23/23.1 8.5 - 1.3 Supplements without G no. (device no.)
Dyn. circuit protection 003 Check lamp, parking brake system
pressure 6.5 + 1.0 004 Pressure gauge, reservoir pressure,
G 27.46 Breather element (snap connection/ circuit 1 and circuit 2
hose) 005 Automatic adjuster
G 27.65 Silencer for valves with snap connection 006 Mechanical emergency release device
G 27.66 Silencer for air dryer with snap 007 Line to the auxiliary consumers
connection 008 Line to air suspension
12.5 bar (not all-wheel drive vehicles) 010
G 50.301 Compressed air reservoir, 30 L EC 011 Electrical activation, auxiliary brake
12.5 bar (all-wheel drive vehicles) system (engine stop)
G 50.302 Compressed air reservoir, 8 L EC 012 Coupling head, reservoir (red)
12.5 bar (all-wheel drive vehicles) 013 Coupling head, brake (yellow)
014
015
3.18 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0780, as of: 12. 01, Heavy Range Trucks, model 26./ 33.XXX FD/FDA, version with trailer brake connection, drum brake on front axle and driven axles.
RA - P 85 3.19 - 1
KEY

Note:

system) with test valve G 61.200 Solenoid valve, air in, NW 2.2
G 10.31 Diaphragm brake cylinder, 3/2-way valve (auxiliary brake system)
G 11.209 Combination brake cylinder, G 67.305 Pressure control module, 2-channel
type 24/30", piston rod 75 mm G 74.300 Position sensor
G 14.202 Overload protection relay 003 Check lamp, parking brake system
G 25.300 Electronically controlled air management 004 Pressure gauge, reservoir pressure,
(ECAM), 12.5 bar (with changeover circuit 1 and circuit 2
hose) 015
connection
RA - P 85 3.20 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0781, as of: 12.01, Heavy Range trucks, model 26./ 33.XXX FD/FDA, version without trailer brake connection, drum brake on front axle and driven axles.
3.19 - 2 RA - P 85
KEY

Note:

G 25.300 Electronically controlled air management reservoir red (single) with closing
(ECAM), 12.5 bar (with changeover element
cartridge, without heater) G 19.4 Coupling head, 2-line
Pressures in bar: Normal mode with reversal protection
Deactivation pressure 12.5 0.3 brake yellow with closing element
Operating range 2.0 - 0.2 G 19.30 Dead coupling, 2-line
Circuit pressure c. 21 12.5 0.3 G 29. 3 Serpentine hose unions,
Circuit pressure c. 24 10.0 +0.5/-2 Supplements without G no. (device no.)
Dyn. circuit protection 002 Check lamp, reservoir, circuit 1 and 2
pressure 6.5 + 1.0 003 Check lamp, parking brake system
G27.46 Breather element (snap connection/ 004 Pressure gauge, reservoir pressure,
hose) circuit 1 and circuit 2
G 27.65 Silencer for valves with snap connection 005 Automatic adjuster
G27.66 Silencer for air dryer with snap 006 Mechanical emergency release device
connection 007 Line to the auxiliary consumers
G 50.300 Compressed air reservoir, 40 L EC 008 Line to air suspension
12.5 bar (not all-wheel drive vehicles) 009
12.5 bar (all-wheel drive vehicles) 011 Electrical activation, auxiliary brake
G 50.302 Compressed air reservoir, 8 L EC system (engine stop)
12.5 bar (all-wheel drive vehicles) 012 Coupling head, reservoir (red)
014
015
3.20 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0785, as of: 12. 01, Heavy Range Trucks, model 38./ 41.XXX FD/FDA, version with trailer brake connection, drum brake on front axle and driven axles.
RA - P 85 3.21 - 1
KEY

Note:

G 14.202 Overload protection relay 003 Check lamp, parking brake system
G 25.300 Electronically controlled air management 004 Pressure gauge, reservoir pressure,
(ECAM), 12.5 bar (with changeover circuit 1 and circuit 2
hose) 015
connection
RA - P 85 3.22 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0786, as of: 12.01, Heavy Range trucks, model 38./ 41.XXX FD/FDA, version without trailer brake connection, drum brake on front axle and driven axles.
3.21 - 2 RA - P 85
KEY

Note:
G 10.300 Diaphragm brake cylinder, right, 3/2-way valve (auxiliary brake system)
type 24" for D-ELSA disc brake G 74.300 Position sensor
G 11.222 Combination brake cylinder, Supplement 1 (with trailer)
G 11.225 Combination brake cylinder, left, with reversal protection
type 30/30", piston rod 200 mm reservoir red (single) with closing
G 25.300 Electronically controlled air management G 19.4 Coupling head, 2-line
(ECAM), 12.5 bar (with changeover with reversal protection
cartridge, without heater) brake yellow with closing element
Pressures in bar: Normal mode G 19.30 Dead coupling, 2-line
Deactivation pressure 12.5 0.3 G 29. 3 Serpentine hose unions,
Operating range 2.0 - 0.2 reservoir/brake (black)
Circuit pressure c. 24 10.0 +0.5/-2 002 Check lamp, reservoir, circuit 1 and 2
Dyn. circuit protection 004 Pressure gauge, reservoir pressure,
pressure 6.5 + 1.0 circuit 1 and circuit 2
hose) 006 Mechanical emergency release device
G 27.65 Silencer for valves with snap connection 007 Line to the auxiliary consumers
G 27.66 Silencer for air dryer with snap 008 Line to air suspension
connection 009
40 L EC (310 x 605) 12.5 bar 011 Electrical activation, auxiliary brake
014
015
3.22 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0787, as of: 10. .01, Heavy Range trucks, model 38./41.XXX DF, version with trailer brake connection, D - ELSA disc brake on front axle and drum brake on driven axles.
RA - P 85 3.23 - 1
KEY

Note:
G 11.224 Combination brake cylinder, right, 001
G 11.225 Combination brake cylinder, left, 003 Check lamp, parking brake system
type 30/30", piston rod 200 mm 004 Pressure gauge, reservoir pressure,
G 14.202 Overload protection relay circuit 1 and circuit 2
G 25.300 Electronically controlled air management 005 Automatic adjuster
(ECAM), 12.5 bar (with changeover 006 Mechanical emergency release device
pressure 6.5 + 1.0 015
hose)
connection
40 L EC (310 x 605) 12.5 bar
30 L EC (310 x 462) 12.5 bar
RA - P 85 3.24 -1
FUNCTION DIAGRAM
Brake system function diagram no. 81.99131.0788, as of: 10.01, Heavy Range trucks, model 38./41.XXX DF, version without trailer brake connection, D - ELSA disc brake on front axle and drum brake on driven axles.
3.23 - 2 RA - P 85
Function diagrams
Overview for
- 4-axle trucks (VF/VFL-Heavy Range, TG-A)
- Disc brakes/drum brakes on the front, leading, trailing and rear axle
- Drum brakes on the front, leading, trailing and rear axle
Vehicle Model Function Trailer Air Special Remarks

models no. diagram Date brake suspension version Page
81.99131 connection
out out
32/41.XXX H 36 0762 09.00 X X Front axle/ 3.51-1 Truck/

VF H 38 rear axle tipper/
D-ELSA semi-
trailer
32/41.XXX H 36 0769 02.01 X X Front axle/ 3.51-2 Truck/
VF H 38 rear axle tipper/
D-ELSA semi-
trailer
32/50.XXX H 36 Front axle
0770 10.01 X X 3.53-1 Truck/
VF H 38 D-ELSA,
tipper/
rear axle
semi-
drum
trailer
brake
0771 10.01 X X 3.53-2 Truck/
VF H 38 D-ELSA,
tipper/
rear axle
semi-
drum
trailer
brake
32/41.XXX H 40 0772 06.01 X X 3.55-1 Truck/
VFL Front axle/
tipper/
rear axle
semi-
D-ELSA
trailer
32/41.XXX H 40 0773 06.01 X X 3.55-2 Truck/
VFL Front axle/
tipper/
rear axle
semi-
D-ELSA
trailer
0774 10.01 X X 3.57-1 Truck/
VFL D-ELSA,
tipper/
rear axle
semi-
drum
trailer
brake
0775 10.01 X X 3.57-2 Truck/
VFL D-ELSA,
tipper/
rear axle
semi-
drum
trailer
brake
RA - P 85 3.50 -1
Vehicle Model Function Trailer brake Air Special Remarks

models no. diagram Date connection suspension version Page
81.99131
out out
32/50.XXX H 38 Front axle/

0782 12.01 X X 3.59-1 Truck/
VF rear drum
tipper/
brake
semitrailer
32/50.XXX H 38 Front axle/
0784 12.01 X X 3.59-2 Truck/
VF rear drum
tipper/
brake
semitrailer
3.50 - 2 RA - P 85
KEY

Note:
suspension), the following supplementary keys: 1. With trailer; 2. With semitrailer; 3. With air springs;
and the supplements without G no. (device number)
G 7.302 Service brake valve, 2-circuit, tandem (circuit I and circuit II) see elec. system
valve G 61.200 Solenoid valve, air in, NW 2.2
type 24" for D-ELSA disc brake Supplement 1 (with trailer)
element
only
cartridge, without heater) G 29. 3 Serpentine hose unions,
pressure 6.5 + 1.0
G 27.46 Breather element (snap connection/ 008 Line to air suspension
hose) 009
connection
40 L EC (310 x 605) 12.5 bar 012
30 L EC (310 x 462) 12.5 bar
014
3.50 - 4 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0762, as of: 09.00, Heavy Range trucks, model 32./41.XXX VF, version with trailer brake connection, D - ELSA disc brake on front and driven axles.
RA - P 85 3.51 - 1
KEY

Note:

G 5.121 Safety valve, 17 + 2 bar G 51.3 Drain valve with pin, without ring
G 7.302 Service brake valve, G 53.3 Filling valve
2-circuit tandem valve G 54.X Test connections
G 8.205 Parking brake valve (parking brake G 55.300 Pressure switch, pneumatic,
system) with test valve NC contact, 5.8 - 0.4 bar
G 10.300 Diaphragm brake cylinder, right, parking brake system for trucks and
type 24", for D-ELSA disc brake buses
G 10.301 Diaphragm brake cylinder, left, G 56.2 Compressed air cylinder for exhaust flap
type 24" for D-ELSA disc brake G 57.2 Pressure gauge (electrical)
G 11.300 Combination brake cylinder, right, (circuit I and circuit II) see elec. system
type 20/24", piston rod 20 mm G 61.200 Solenoid valve, air in, NW 2.2
G 11.301 Combination brake cylinder, left, 3/2-way valve (auxiliary brake system)
type 20/24", piston rod 20 mm G 67.304 Pressure control module, 1-channel
G 14.300 PA relay valve, for parking brake system G 67.305 Pressure control module, 2-channel
only G 74.300 Position sensor
G 25.300 Electronically controlled air management Supplements without G no. (device no.)
cartridge, without heater) 002 Check lamp, reservoir, circuit 1 and 2
Pressures in bar: Normal mode 003 Check lamp, parking brake system
Deactivation pressure 12.5 0.3 004 Pressure gauge, reservoir pressure,
Operating range 2.0 - 0.2 circuit 1 and circuit 2
Circuit pressure c. 24 10.0 +0.5/-2 007 Line to the auxiliary consumers
Circuit pressure c. 25 12.5 0.3 008 Line to air suspension
pressure 6.5 + 1.0 010
G 27.46 Breather element (snap connection/ 011 Electrical activation, auxiliary brake
hose) system (engine stop)
G 27.65 Silencer for valves with snap connection 012 Coupling head, reservoir (red)
G 27.66 Silencer for air dryer with snap 013 Coupling head, brake (yellow)
connection 014
015
RA - P 85 3.52 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0769, as of: 02.01, Heavy Range trucks, model 32./41.XXX VF, version without trailer brake connection, D - ELSA disc brake on front and driven axles.
3.51 - 2 RA - P 85
KEY

Note:
(single) with closing element
G 22.200 Quick-release valve with reversal protection
G 25.300 Electronically controlled air management brake yellow with closing element
(ECAM), 12.5 bar (with changeover G 19.30 Dead coupling, 2-line
Pressures in bar: Normal mode reservoir/brake (black)
001
Circuit pressure c. 24 10.0 +0.5/-2 004 Pressure gauge, reservoir pressure,
G 27.46 Breather element (snap connection/ 007 Line to the auxiliary consumers
30 L EC (310 x 462) 12.5 bar 014
015
3.52 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0770, as of: 10.01, Heavy Range trucks, model 32./50.XXX VF, version with trailer brake connection, D - ELSA disc brake on front axles and drum brake on driven axles.
RA - P 85 3.53 - 1
KEY

Note:

G 5.67 Pressure limiting valve 20/3.5 +0.2 bar G 51.3 Drain valve with pin, without ring
system) with test valve NC contact, 5.8 - 0.4 bar
G 10.300 Diaphragm brake cylinder, right, parking brake system for trucks and
type 24", for D-ELSA disc brake buses
G 10.301 Diaphragm brake cylinder, left, G 56.2 Compressed air cylinder for exhaust flap
type 24" for D-ELSA disc brake G 57.2 Pressure gauge (electrical)
G 11.300 Combination brake cylinder, right, (circuit I and circuit II) see elec. system
G 11.320 Combination brake cylinder, right, G 74.300 Position sensor
G 22.200 Quick-release valve 001
G 25.300 Electronically controlled air management 002 Check lamp, reservoir, circuit 1 and 2
(ECAM), 12.5 bar (with changeover 003 Check lamp, parking brake system
cartridge, without heater) 004 Pressure gauge, reservoir pressure,
Pressures in bar: Normal mode circuit 1 and circuit 2
Deactivation pressure 12.5 0.3 005 Automatic adjuster
Circuit pressure c. 23/23.1 8.5 - 1.3 008 Line to air suspension
pressure 6.5 + 1.0
G 27.46 Breather element (snap connection/ 012 Coupling head, reservoir (red)
hose) 013 Coupling head, brake (yellow)
014
015
connection
RA - P 85 3.54 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0771, as of: 10.01, Heavy Range trucks, model 32./50.XXX VF, version without trailer brake connection, D - ELSA disc brake on front axles and drum brake on driven axles.
3.53 - 2 RA - P 85
KEY

Note:
G 5.121 Safety valve, 17 + 2 bar NC contact, 5.8 - 0.4 bar
G 7.302 Service brake valve, parking brake system for trucks and
2-circuit tandem valve buses
G 8.205 Parking brake valve (parking brake G 56.2 Compressed air cylinder for exhaust flap
system) with test valve G 57.2 Pressure gauge (electrical)
G 10.300 Diaphragm brake cylinder, right, (circuit I and circuit II) see elec. system
type 24", for D-ELSA disc brake G 57.300 Pressure sensor, see elec. system
G 10.301 Diaphragm brake cylinder, left, G 61.200 Solenoid valve, air in, NW 2.2
type 24" for D-ELSA disc brake 3/2-way valve (auxiliary brake system)
type 20/24", piston rod 20 mm G 17.301 Trailer control module 2-line
G 11.320 Combination brake cylinder, right, G 19.3 Coupling head, 2-line
element
only
G 25.300 Electronically controlled air management brake yellow with closing element
Operating range 2.0 - 0.2 Supplements without G no. (device no.)
Circuit pressure c. 24 10.0 +0.5/-2 004 Pressure gauge, reservoir pressure,
G 27.46 Breather element (snap connection/ 007 Line to the auxiliary consumers
30 L EC (310 x 462) 12.5 bar 014
015
3.54 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0772, as of: 06.01, Heavy Range trucks, model 32./41.XXX VFL, version with trailer brake connection, D - ELSA disc brake on front and driven axles.
RA - P 85 3.55 - 1
KEY

Note:
G 5.121 Safety valve, 17 + 2 bar G 51.3 Drain valve with pin, without ring
G 7.302 Service brake valve, G 53.3 Filling valve
system) with test valve NC contact, 5.8 - 0.4 bar (parking brake
G 10.300 Diaphragm brake cylinder, right, system)
type 24", for D-ELSA disc brake G 56.2 Compressed air cylinder for exhaust flap
G 10.301 Diaphragm brake cylinder, left, G 57.2 Pressure gauge (electrical)
type 24" for D-ELSA disc brake (circuit I and circuit II) see elec. system
G 11.300 Combination brake cylinder, right, G 57.300 Pressure sensor, see elec. system
type 20/24", piston rod 20 mm 001
G 14.300 PA relay valve, for parking brake system 002 Check lamp, reservoir, circuit 1 and 2
only 003 Check lamp, parking brake system
G 22.200 Quick-release valve 004 Pressure gauge, reservoir pressure,
Circuit pressure c. 23/23.1 8.5 - 1.3 011 Electrical activation, auxiliary brake
Circuit pressure c. 24 10.0 +0.5/-2 system (engine stop)
Circuit pressure c. 25 12.5 0.3 012 Coupling head, reservoir (red)
Dyn. circuit protection 013 Coupling head, brake (yellow)
pressure 6.5 + 1.0 014
hose)
connection
RA - P 85 3.56 -1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0773, as of: 06.01, Heavy Range trucks, model 32./41.XXX VFL, version without trailer brake connection, D - ELSA disc brake on front and driven axles.
3.55 - 2 RA - P 85
KEY

Note:

G 11.209 Combination brake cylinder, Supplement 1 (with trailer)
G 11.221 Combination brake cylinder, left, with reversal protection
type 24/30", piston rod 200 mm reservoir red (single) with closing
G 22.200 Quick-release valve G 19.4 Coupling head, 2-line
G 25.300 Electronically controlled air management with reversal protection
(ECAM), 12.5 bar (with changeover brake yellow with closing element
cartridge, without heater) G 19.30 Dead coupling, 2-line
Pressures in bar: Normal mode G 29. 3 Serpentine hose unions,
Deactivation pressure 12.5 0.3 reservoir/brake (black)
Circuit pressure c. 23/23.1 8.5 - 1.3 002 Check lamp, reservoir, circuit 1 and 2
Circuit pressure c. 24 10.0 +0.5/-2 003 Check lamp, parking brake system
Circuit pressure c. 25 12.5 0.3 004 Pressure gauge, reservoir pressure,
Dyn. circuit protection circuit 1 and circuit 2
pressure 6.5 + 1.0 005 Automatic adjuster
G 27.46 Breather element (snap connection/ 006 Mechanical emergency release device
hose) 007 Line to the auxiliary consumers
G 27.65 Silencer for valves with snap connection 008 Line to air suspension
connection 010
G 50.300 Compressed air reservoir 011 Electrical activation, auxiliary brake
40 L EC (310 x 605) 12.5 bar system (engine stop)
G 50.301 Compressed air reservoir 012 Coupling head, reservoir (red)
30 L EC (310 x 462) 12.5 bar 013 Coupling head, brake (yellow)
014
015
3.56 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0774, as of: 10. 01, Heavy Range trucks, model 32./41.XXX VFL, version with trailer brake connection, D - ELSA disc brake on front axles and drum brake on driven axles.
RA - P 85 3.57 - 1
KEY

Note:

G 5.67 Pressure limiting valve 20/3.5 +0.2 bar G 51.3 Drain valve with pin, without ring
G 5.121 Safety valve, 17 + 2 bar G 53.3 Filling valve
G 7.302 Service brake valve, G 54.X Test connections
2-circuit tandem valve G 55.300 Pressure switch, pneumatic,
G 8.205 Parking brake valve (parking brake NC contact, 5.8 - 0.4 bar (parking brake
system) with test valve system)
G 10.300 Diaphragm brake cylinder, right, G 56.2 Compressed air cylinder for exhaust flap
type 24", for D-ELSA disc brake G 57.2 Pressure gauge (electrical)
G 10.301 Diaphragm brake cylinder, left, (circuit I and circuit II) see elec. system
type 24" for D-ELSA disc brake G 57.300 Pressure sensor, see elec. system
G 11.209 Combination brake cylinder, G 61.200 Solenoid valve, air in, NW 2.2
type 24/30", piston rod 75 mm 3/2-way valve (auxiliary brake system)
G 14.202 Overload protection relay 001
G 22.200 Quick-release valve 002 Check lamp, reservoir, circuit 1 and 2
G 25.300 Electronically controlled air management 003 Check lamp, parking brake system
(ECAM), 12.5 bar (with changeover 004 Pressure gauge, reservoir pressure,
cartridge, without heater) circuit 1 and circuit 2
Pressures in bar: Normal mode 005 Automatic adjuster
Deactivation pressure 12.5 0.3 006 Mechanical emergency release device
Dyn. circuit protection system (engine stop)
pressure 6.5 + 1.0 012 Coupling head, reservoir (red)
G 27.46 Breather element (snap connection/ 013 Coupling head, brake (yellow)
hose) 014
connection
RA - P 85 3.58 -1
FUNCTION DIAGRAM
Brake system function diagram no. 81.99131.0775, as of: 10.01, Heavy Range trucks, model 32./41.XXX VFL, version without trailer brake connection, D - ELSA disc brake on front axles and drum brake on driven axles.
3.57 - 2 RA - P 85
KEY

Note:

G 5.67 Pressure limiting valve, 20/3.5 +0.2 bar NC contact, 5.8 - 0.4 bar (parking brake
G 22.200 Quick-release valve reservoir red (single) with closing
element
(ECAM), 12.5 bar (with changeover G 19.4 Coupling head, 2-line
cartridge, without heater) with reversal protection
Deactivation pressure 12.5 0.3 G 19.30 Dead coupling, 2-line
Operating range 2.0 - 0.2 G 29. 3 Serpentine hose unions,
Circuit pressure c. 22 12.5 0.3 Supplements without G no. (device no.)
Dyn. circuit protection 003 Check lamp, parking brake system
pressure 6.5 + 1.0 004 Pressure gauge, reservoir pressure,
hose)
connection 008 Line to air suspension
40 L EC (310 x 605) 12.5 bar 010
G 50.301 Compressed air reservoir 011 Electrical activation, auxiliary brake
30 L EC (310 x 462) 12.5 bar system (engine stop)
014
015
3.58 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0782, as of: 12.01, Heavy Range trucks, model 32./50.XXX VF, version with trailer brake connection, drum brakes on front and driven axles.
RA - P 85 3.59 - 1
KEY
Key to brake system function diagram no.: 81.99131.0784, as of: 12. 01, Heavy Range Trucks, model 32./ 50.XXX VF, version with trailer brake connection, drum brakes on front and driven axles.
Note:
2. The key is split up into several sections. It consists of the basic version (without trailer, without air springs) and the following supplementary keys: 1. With trailer; 2. With semitrailer; 3. With air springs; and the supplements without G no.
(device no.)

G 27.46 Breather element (snap connection/hose) Supplements without G no. (device no.)
G 1.1 Air compressor, one-cylinder, 361 cc, for vehicles
with leaf suspension G 27.65 Silencer for valves with snap connection 001
G 1.2 Air compressor, two-cylinder, 585 cc, for vehicles G 27.66 Silencer for air dryer with snap connection 002 Check lamp, reservoir, circuit 1 and 2
with air suspension G 50.300 Compressed air reservoir 003 Check lamp, parking brake system
G 5.67 Pressure limiting valve, 20/3.5 + 0.2 bar 40 L EC (310 x 605) 12.5 bar 004 Pressure gauge, reservoir pressure,
G 5.121 Safety valve, 17 + 2 bar G 50.301 Compressed air reservoir circuit 1 and circuit 2
30 L EC (310 x 462) 12.5 bar 005 Automatic adjuster
2-circuit tandem valve G 51.3 Drain valve with pin, without ring 006 Mechanical emergency release device
G 8.205 Parking brake valve (parking brake system) G 53.3 Filling valve 007 Line to the auxiliary consumers
with test valve G 54.X Test connections 008
G 10.31 Diaphragm brake cylinder, type 27", G 55.300 Pressure switch, pneumatic, 009
piston rod 37 mm NC contact, 5.8 - 0.4 bar (parking brake system) 010
G 11.209 Combination brake cylinder, type 24/30", G 56.2 Compressed air cylinder for exhaust flap 011 Electrical activation, auxiliary brake system (engine
piston rod 75 mm G 57.2 Pressure gauge (electrical) stop)
G 11.220 Combination brake cylinder, right, type 24/30", (circuit I and circuit II) see elec. system 012
piston rod 200 mm G 61.200 Solenoid valve, air in, NW 2.2 013
G 11.221 Combination brake cylinder, left, type 24/30", 3/2-way valve (auxiliary brake system)
014
piston rod 200 mm G 67.304 Pressure control module, 1-channel
015
G 14.202 Overload protection relay G 67.305 Pressure control module, 2-channel
G 22.200 Quick-release valve G 74.300 Position sensor
G 25.300 Electronically controlled air management (ECAM),
12.5 bar (with changeover cartridge, without heater)
Circuit pressure c. 24 10.0 + 0.5/-2
Dyn. circuit protection pressure 6.5 + 1.0
RA - P 85 3.60 - 1
FUNCTION DIAGRAM
Brake system function diagram no.: 81.99131.0784, as of: 12.01, Heavy Range trucks, model 32./ 50.XXX VF, version without trailer brake connection, drum brakes on front and driven axles.
3.59 - 2 RA - P 85
KEY
Key to brake system function diagram no.: 82.99131.8602, as of: 03.02, Heavy Range trucks, model 41..XXX FVD , model code no. H 95, heavy-duty tractor, version with trailer brake connection, MERITOR D - ELSA II disc brake on front
axle, drum brakes on leading axle and on driven axles.
Key
G 1.2 Air compressor, 2-cylinder G 27.63 Silencer (M 22 x 1.5) xxx
G 4.6 Multi-circuit protection valve, 5 connections G 27.65 Silencer for valves with snap lock 001
(protection pressure, circuit 1+2+4 = 6.9 - 0.3 bar, 002 Check lamp, reservoir, circuit 1 and 2
G 27.66 Silencer for air dryer with snap lock
circuit 3 = 7.0 - 0.3 bar, closing pressure 6.4 bar) 003 Check lamp, parking brake system
G 50.300 Compressed air reservoir 004 Pressure gauge, reservoir pressure,
G 5.67 Pressure limiting valve, 20/3.5 + 0.2 bar 40 L EC (310 x 605) 12.5 bar circuit 1 and circuit 2
G 5.121 Safety valve for air compressor 17.0 + 2.0 bar G 51.3 Drain valve with pin, without ring 005 Automatic adjuster
G 5.200 Pressure limiting valve, 8.5 - 0.4 bar 006 Mechanical emergency release device
G 53.3 Filling connection, filling valve
G 5.201 Pressure limiting valve, 10.0 0.3 bar G 54.X Test connection 008 Line to air suspension
G 6.6 Overflow valve with limited return flow, G 55.300 Pressure switch, pneumatic 009 Line from G 73. Connection 25, see air suspension
6.4 - 0.3 bar NC contact, 5.8 - 0.4 bar function diagram
G 7.302 Service brake valve, EBS with Voss 232 parking brake system for trucks and buses 010 For BLBB, see detail A
G 57.2 Pressure gauge 011 Auxiliary brake valve, see engine,
G 8.205 Parking brake valve with test position
electrical activation, auxiliary brake system (engine
G 10.300 Diaphragm cylinder for disc brake, G 57.300 Pressure sensor stop)
MERITOR-D-ELSA, type 24, right G 57.301 Pressure sensor 012 Coupling head, reservoir (red)
G 10.301 Diaphragm cylinder for disc brake, 013 Coupling head, brake (yellow)
G 62.201 Solenoid valve, air out (3/2-way valve)
MERITOR-D-ELSA, type 24, left 014 Line from G 73. Connection 25, see air suspension
G 67.304 Pressure control module, 1-channel for EBS function diagram
G 10.xxx Diaphragm cylinder for leading axle, left and right
MAN part no. 82.51101-6026 G 67.305 Pressure control module, 2-channel for EBS 015
I Reservoir, circuit I, front axle
G 11.222 Combination cylinder, left, type 30/30, II Reservoir, circuit II, rear axle
piston rod 75 mm Supplement 1 (with trailer) III Reservoir, circuit III, parking brake system + trailer
G 11.224 Combination cylinder, right, type 30/30, IV Reservoir, auxiliary consumers
piston rod 200 mm G 17.301 Trailer control module, 2-line V Reservoir, air suspension system
G 11.225 Combination cylinder, left, type 30/30, G 19.3 Coupling head, 2-line (xxxx) See electrical diagram
piston rod 200 mm with reversal protection
reservoir red (single) with closing element
G 14.65 Relay valve, connection 3 = M 22 x 1.5
G 21.11 Shuttle valve, double check valve, brake yellow with closing element
low pressure-opened G 19.30 Dead coupling, 2-line
G 23.203 Double check valve G 29. 3 Serpentine hose unions, reservoir/brake
G 24.9 Vent valve (3/2-way valve) for BLLL (black) for semitrailer tractor
G 25.xxx Air dryer with pressure regulator 12.5 0.2 bar

(changeover cartridge; with heating)
MAN part no. 82.52102-6034
3.60 - 2 RA - P 85
FUNCTION DIAGRAM
Brake system function diagram no.: 82.99131.8602, as of: 12.01, Heavy Range trucks, model 41..XXX FVD , model code no. H 95, heavy-duty tractor, version with trailer brake connection, MERITOR D - ELSA disc brake on front axle, drum
brakes on leading axle and on driven axles.
RA - P 85 3.61 - 1
SUPPLEMENTARY FUNCTION DIAGRAMS
Supplementary Function Diagrams
10. 2002
RA - P 85 5.00 -1
OVERVIEW, SUPPLEMENTARY FUNCTION DIAGRAMS
Supplementary function diagrams

Overview for
2, 3 and 4-axle trucks, with leaf and air suspension (Heavy Range, TG-A)
Vehicle Model Function Designation Date Page Remarks

models Weight diagram no.
category 81.99131.
0678 DUOMATIC 05. 02. 01 5.11 - 1

coupling head
H09, H14, H16 0698 Additional 02.01 5.11 - 2
H17, H19, H20 reservoir for air
H23, H27, H31 suspension
H44, H86,
0699 Emergency 11.98 5.12 - 1

release device
H02, H05, H06 Compressed air
H07, H09, H12 0700 connection for 04.01 5.12 - 2
H14, H16, H17 auxiliary
H19, H20, H23 consumers on
H25, H26, H27 body
H28, H29, H31
H32, H36, H38
H40, H44, H51
H55, H70, H72
H73, H76, H86
H88, H94, H95
H02, H05, H06 0701 Independent trailer 02.01 5.13 - 1 Netherlands, Norway
H07, H09, H12 brake
H14, H16, H17
H19, H20, H23
H25, H26, H27
H28, H29, H31
H32, H36, H38
H40, H44, H51
H55, H61, H70
H72, H73, H76
H86, H88,
H94, H95
H05, H06, H07 Trailer brake
H09, H12, H17 0702 connection at 07.99 5.13 - 2 Semitrailer tractors
H20, H23, H25 frame end
H28, H29, H32
H51, H55, H70
H72, H86,
H94, H95,
H02, H05, H06 0703 Brake system 07.99 5.14 - 1
H07, H09, H12 Switzerland
H14, H16, H17
H19, H20, H23
H25, H26, H29
H36, H38, H40
H44, H51, H55
H70, H72, H73
H76, H86, H88
H94, H95,
RA - P 85 5.10 -1

category 81.99131.
H02, H05, H06 Dual-line brake
H07, H09, H12 0710 connection, front 05.00 5.14 - 2
H14, H16, H17
H19, H20, H23
H25, H26, H27
H28, H29, H31
H32, H36, H38
H40, H44, H51
H55, H70, H72
H73, H76
H86, H88
H94, H95
H02, H05, H09 0745 Controlled engine 05.00 5.15 - 1
H12, H14, H17 brake
H20, H23, H25
H29, H44, H51
H55, H70, H72
H86, H94
H02, H05, H06 0750 TG-A with 10.01
H07, H09, H12 air dryer 5.15 - 2
H14, H16, H17
H19, H20, H23
H25, H26, H27
H28, H29, H31
H32, H36, H38
H40, H44, H51
H55, H61, H70
H72, H73, H76
H86, H88, H94
H05, H06, H07 Additional 5.16 - 1

H09, H12, H51 0751 compressed air 09.00
reservoir with
larger tank volume
H02, H05, H06 2/3-axle 0763 Front axle - 11.01 5.16 - 2
H07, H09, H12 vehicle parking brake
H14, H16, H17
H19, H20, H23
H25, H26, H27
H28, H29, H31
H44, H86, H94
H95
H25, H26, H28 0776 TG-A with 06.01
H29, H55, 2-chamber air 5.17 - 1
dryer
H02, H05, H06 Additional line filter 5.17 - 2
H07, H09, H12 0789 in air compressor 10.01
H14, H16, H17 cooling line
H19, H20, H23
H25, H26, H28
H29, H32, H36
H38, H40, H44
H51, H55, H61
H70, H72, H73
H76, H86, H88
H94, H95
5.10 - 2 RA - P 85

category 81.99131.
H02, H05, H06 0791 TG-A with air dryer 5.18 - 1 TG-A - solo vehicles
H07, H09, H16
H17, H19, H20
H23, H25, H27
H29, H31, H32
H36, H38, H40
H51, H55, H70
H73, H76
H86, H88,
H 95 41.XXX 82.99131- Additional air 01.02 Heavy-duty tractor

FVD 8606 compressor 5.18 - 2
H02, H05, H06 0717 Electronically 11.98 5.19 - 1
H07, H09, H12 controlled air
H14, H16, H17 management
H19, H20, H23 (ECAM) with
H25, H26, H27 heater
H29, H31, H32
H36, H38, H40
H44, H51, H55
H70, H72, H73
H76, H86, H88
H02, H05, 0184 Trailer brake 11.98 5.19 - 2 Heavy-duty tractor

H09, H14, connection,
H16, H17, Norway
H19, H20,
H23, H25,
H26, H29,
H36, H38,
H40, H44,
H51, H55,
H72, H73,
H76, H86,
H88,
RA - P 85 5.10 -3
Brake system supplementary function diagram no.: 81.99131.0678, as of: 05. 02. 01, additional diagram for Duomatic coupling head, Heavy Range trucks
Key:
G 17.xxx Trailer control valve, 2-line brake
G 19.3 Coupling head, reservoir 001 Coupling head, reservoir Omitted
G 19.4 Coupling head, brake 002 Coupling head, brake Omitted
G 19.12 Duomatic coupling head
See vehicle-specific brake function diagram for devices without G number (device number)
RA - P 85 5.11 - 1
Brake system supplementary function diagram no.: 81.99131.0698, as of: 02. 01, additional reservoir for air suspension, Heavy Range trucks, model BL/LL/HLL
Key:
For 2-axle vehicles (4 x 2) LL For 3-axle vehicles (6 x 2) BL For 3-axle vehicles (6 x 2) LL
G 25.xxx Electr. controlled air management (ECAM) G 25.xxx Electr. controlled air management (ECAM) G 25.xxx Electr. controlled air managmt. (ECAM)
G 50.300 Compressed air reservoir, 40 l EC, 12.5 bar G 50.300 Compressed air reservoir 40 l EC, 12.5 bar G 50.300 Compr. air reservoir 40 l EC, 12.5 bar
G 51.3 Drain valve with pin G 51.3 Drain valve with pin G 50.301 Compr. air reservoir 30 l EC, 12.5 bar
G 54.x Test connections G 54.x Test connections G 51. Drain valve with pin
001 For vehicles with air dryer 001 For vehicles with air dryer 001 For vehicles with air dryer
002 For vehicles with ECAM 002 For vehicles with ECAM 002 For vehicles with ECAM
008 Line, reservoir to air suspension 008 Line, reservoir to air suspension 008 Line, reservoir to air suspension
RA - P 85 5.11 - 2
Brake system supplementary function diagram no. 81.99131.0699, status as of: 08. 98, emergency release device, Heavy Range trucks
Key:
G 8.206 Parking brake valve with test valve G 14.xxx Relay valves G 21.201 Shuttle valve (2-way valve)
G 25.xxx Elect. controlled air management (ECAM) G 55.xxx Pressure switch, pneumatic G 55.200 Pressure switch, pneum. (NC contact)
G 61.202 Solenoid valve, air in (3/2-way valve) 001 Warning light, reservoir pressure 003 Warning light, parking brake
015 Solo vehicles have dummy plug 018 Lines to rear axle spring actuators
RA - P 85 5.12 - 1
Brake system supplementary function diagram no.: 81.99131.0700, as of: 08. 98, compressed air connection for auxiliary consumers on body, Heavy Range trucks
Key:
001 Line from air dryer
G 4.... Multi-circuit protection valve (see brake function diagram)
002 For vehicles with air dryer
G 5.... Pressure limiting valves 10 0,3 bar (see brake function diagram)
G 6.4 Overflow valve, full return flow, 7.3 - 0.3 bar 003 For vehicles with ECAM system
G 6.6 Overflow valve with limited return flow, 6.4 - 0.3 bar 004 Line to ASTRONIC (for Astronic only)
(for Astronic only) 005 Connection for auxiliary consumers (with dummy plug)
G 23.1 Check valve (for Astronic only) 017 Distributor, auxiliary consumers (MAN no. 81.98183.6000)
on solenoid valve block (connection M 16 x 1.5 with
G 25.xxx Electronically controlled air management (ECAM)
dummy plug)
G 57.... Pressure gauge/pressure sensor (see brake function diagram)
See vehicle-specific brake function diagram for devices
without G number (device number)
RA - P 85 5.12 - 2
Brake system supplementary function diagram no. 81.99131.0701, status as of: 09.98, independent trailer brake, Heavy Range trucks
Key:
G 8.xxx Parking brake valve 001 Line from reservoir, parking brake system 004 To coupling head, reservoir
G 8.301 Independent trailer brake valve 003 Pressure limiter, independent trailer brake 005 To coupling head, brake
G 17.xxx Trailer control module See national directives in See vehicle-specific brake function
various states, these currently apply for devices without G number (device number)
to: Norway = 2.7 bar
Netherlands = 2.5 bar
RA - P 85 5.13 - 1
Brake system supplementary function diagram no.: 81.99131.0702, as of: 09. 98, brake connection at frame end for semitrailer tractors, Heavy Range trucks
Key:
G 17.xxx Trailer control module G 19.xxx Coupling head G 19.3 Coupling head, reservoir (red)
G 19.4 Coupling head, brake (yellow) G 29.xxx Serpentine hose union
001 2-line brake, reservoir (red) 002 2-line brake, brake (yellow)
RA - P 85 5.13 - 2
Brake system supplementary function diagram no.: 81.99131.0703, as of: 07. 99, brake system, Switzerland, Heavy Range trucks.
Key:
G 5.5 Pressure limiting valve, 10/5.9 + 0.2 bar 001 EC 2-line brake (reservoir, red)
G 17.... Trailer control module 002 EC 2-line brake (brake, yellow)
G 18.4 Trailer control valve, 1-line brake 003 CH 2-line brake
without pressure limiter, without lead (Switzerland) 004 CH 2-line brake, control line (brake, yellow)
G 19.3 Coupling head, reservoir (single) with closing element 005 CH 2-line brake, feed line (reservoir, red)
G 19.4 Coupling head, brake with closing element Coupling heads not supplied by MAN
G 19.30 Coupling head, dead coupling, 2-line Lines with dummy plugs.
G 29.3 Serpentine hose unions, reservoir/brake, black (for semitrailer only)
RA - P 85 5.14 - 1
Brake system supplementary function diagram no.: 81.99131.0710, as of: 09. 98, 2-line brake connection, front, for vehicles with existing brake connection, rear.
Key:
G 4.xxx Multi-circuit protection valve G 23.1 Check valves
G 5.xxx Pressure limiting valve G 25.xxx Electronically controlled air management
G 17.301 Trailer control module 001 For vehicles with air dryer
G 19.3 Coupling head, reservoir (red) 002 For vehicles with ECAM system
G 19.4 Coupling head, brake (yellow) 003 2-line brake, reservoir (red)
004 2-line brake, brake (yellow)
RA - P 85 5.14 - 2
Brake system supplementary function diagram no.: 81.99131.0745, as of: 05. 00, controlled engine brake, Heavy Range trucks.
Key:
G 4.xxx Multi-circuit protection valve 001 Line from air dryer
G 5.xxx Pressure limiting valve 002 Line from air compressor
G 25.xxx Electronically controlled air management (ECAM) 003 For vehicles with air dryer
G 54.x Test connections 004 For vehicles with ECAM system
G 56.2 Compressed air cylinder for exhaust flap 005 Proportional valve (supplied with engine brake)
G 57.xxx Pressure gauges/pressure sensors 006 Line, reservoir for further auxiliary consumers
RA - P 85 5.15 - 1
Brake system supplementary function diagram no. 81.99131.0750, status as of: 10. 01, TG-A vehicles with air dryer, Heavy Range trucks.
Key:
G 4.6 Multi-circuit protection valve (for 3-axle vehicle >35 t) G 50.29 Compressed air reservoir, 20l, 12.5 bar 005 Line to reservoir circuit I
G 4.7 Multi-circuit protection valve (closing pressure 6.4 bar) G 50.40 Compressed air reservoir, 4l, 12.5 bar 006 Line to reservoir circuit II
G 5.200 Pressure limiting valve, 8.5 - 0.4 bar G 51.3 Drain valve with pin, without ring 007 Line to G 8.xxx connection 1
G 5.201 Pressure limiting valve, 10 0.3 bar G 53.3 Filling valve 008 Line to G 14.xxx connection 1
G 23.201 Double check valve G 54.x Test connections 009 Line to G 17.xxx connection 11
G 25.203 Air dryer without heater G 57.301 Pressure sensor 010 * For additional equipment only
G 25.205 Air dryer with heater 001 Line from air compressor Brake system Switzerland
G 27.47 Breather element, snap connection/hose 002 For air suspension only Dual-line brake connection, front,
G 27.66 Silencer for air dryer with 003 Line to reservoir, air suspension brake connection at frame
snap connection 004 Line to reservoir, auxiliary consumers end for semitrailer tractor
RA - P 85 5.15 - 2
Brake system supplementary function diagram no.: 81.99131.0751, as of: 09. 00, additional compressed air reservoirs for larger tank volume, Heavy Range trucks.
Key:
G 4.xxx Multi-circuit protection valve 001 For vehicles with ECAM system
G 25.xxx Electronically controlled air management (ECAM) 002 For vehicles with air dryer
G 50.304 Compressed air reservoir, 20l, 12.5 bar 003 Line to G 7.xxx connection 12
G 51.3 Drain valve with pin, without ring 004 Line to G 67.xxx connection 1
G 54.x Test connections
G 57.xxx Pressure gauges/pressure sensors
RA - P 85 5.16 - 1
Brake system supplementary function diagram no. 81.99131.0763, as of:11. 01, parking brake on the front axle, Heavy Range trucks.
Key:
G 4.xxx Multi-circuit protection valve G 23.xxx Check valves 005 For solo vehicles
G 5.xxx Pressure limiting valve G 25.xxx Electronically controlled air management (ECAM) 006 Line to G 14.xxx connection 1
G 8.xxx Parking brake valve G 27.40 Bleed valve (M 22 x 1.5) 007 Line to G 8.xxx connection 1
G 8.xxx Independent trailer brake valve G 27.65 Silencer for valves 008 For vehicles with trailer control
G 10.xxx Diaphragm cylinder with snap connection 009 For vehicles with indepnt. trailer brake
G 17.xxx Trailer control valve G 67.xxx Pressure control module
G 17.201 Trailer control valve 001 For vehicles with ECAM system
Without lead 002 For vehicles with air dryer
G 21.300 Shuttle valve with 003 Line to G 8.xxx connection 1
return flow 004 Line to G 14.xxx connection 1
RA - P 85 5.16 - 2
Brake system supplementary function diagram no.: 81.99131.0776, as of: 06. 01, TG-A with 2-chamber air dryer, Heavy Range trucks.
Key:
G 4.6 Multi-circuit protection valve (for 3-axle vehicle >35 t) G 50.40 Compressed air reservoir, 4l, 12.5 bar 008 Line to G 14.xxx connection 1
G 4.7 Multi-circuit protection valve (closing pressure 6.4 bar) G 51.3 Drain valve with pin, without ring 009 Line to G 17.xxx connection 11
G 5.200 Pressure limiting valve, 8.5 - 0.4 bar G 53.3 Filling valve 010 * For additional equipment only
G 5.201 Pressure limiting valve, 10 0.3 bar G 57.301 Pressure sensor Brake system Switzerland
G 23.201 Double check valve 001 Line from air compressor Dual-line brake connection, front,
G 25.39 2-chamber air dryer with pressure regulator 002 For air suspension only brake connection at frame
and heater, 12.5 bar 003 Line to reservoir, air suspension end for semitrailer tractor
G 27.47 Breather element, snap connection/hose 004 Line to reservoir, auxiliary consumers
G 27.66 Silencer for air dryer with 005 Line from reservoir circuit I
snap connection 006 Line to reservoir circuit II
G 50.29 Compressed air reservoir, 20l, 12.5 bar 007 Line to G 8.xxx connection 1
RA - P 85 5.17 - 1
Brake system supplementary function diagram no.: 81.99131.0789, as of: 10. 01, line filter in cooling line from air compressor, Heavy Range trucks.
Key:
G 1.xxx Air compressor
001 Line to ECAM or air dryer
RA - P 85 5.17 - 2
Brake system supplementary function diagram no.: 81.99131.0791, as of: 01. 02, TG-A with air dryer for solo vehicles, Heavy Range trucks.
Key:
G 4.6 Multi-circuit protection valve (for 3-axle vehicle >35 t) G 50.40 Compressed air reservoir, 4l, 12.5 bar 004 Line to reservoir, auxiliary consumers
G 4.7 Multi-circuit protection valve (closing pressure 6.4 bar) G 53.3 Filling valve 005 Line to reservoir circuit I
G 5.200 Pressure limiting valve, 8.5 - 0.4 bar G 54.x Test connections 006 Line to reservoir circuit II
G 5.201 Pressure limiting valve, 10 0.3 bar G 57.301 Pressure sensor 007 Line to G 8.xxx connection 1
G 25.203 Air dryer without heater 008 Line to G 14.xxx connection 1
G 25.205 Air dryer with heater
G 27.47 Breather element, snap connection/hose 001 Line from air compressor
G 27.66 Silencer for air dryer with 002 For air suspension only
snap connection 003 Line to reservoir, air suspension
RA - P 85 5.18 - 1
Brake system supplementary function diagram no.: 82.99131.8606, as of: 01. 02, auxiliary air compressor for TG-A heavy-duty tractor model H 95, Heavy Range trucks.
Key:
G 1.2 2-cyl. air compressor G 51.3 Drain valve with pin, without ring
G 5.121 Safety valve, 17+2 bar G 62.201 Solenoid valves, air out (3/2-way valve)
G 27.xxx Silencer 001 Line to 4-circuit protection valve, connection 1
G 50.64 Compressed air reservoir, 1l, 12.5 bar 002 Line to reservoir, air suspension
G 50.300 Compressed air reservoir, 40 l, 12.5 bar 003 Line angled downwards to the solenoid valve.
RA - P 85 5.18 - 2
Brake system supplementary function diagram no.: 81.99131.0717, as of: 11. 98, electronically controlled air management (ECAM) with heater, Heavy Range trucks.
Key:
G 25.301 Electronically controlled air management (ECAM) with heater
RA - P 85 5.19 - 1
Brake system supplementary function diagram no.: 81.99131.0184, as of: 02. 89, trailer brake connection, Norway, Heavy Range trucks.
Key:
G 17.xxx Trailer control module G 19.3 Coupling head, reservoir (red) G 19.4 Coupling head, brake (yellow)
003 Line from compressed air reservoir 012 2-line brake, reservoir (red) 013 2-line brake, brake (yellow)
RA - P 85 5.19 - 2
AIR SUSPENSION DIAGRAMS
Air Suspension Installation Diagrams

Air Suspension Function Diagrams
10. 2002
RA - P 85 6.00 -1
OVERVIEW, AIR SUSPENSION INSTALLATION DIAGRAMS
Air suspension installation diagrams

Overview for
- 2, 3 and 4-axle trucks (Heavy Range, TG-A)
- Pneumatically braked front, leading/trailing and rear axle
Vehicle Function Date Swap-body Air Special Page Remarks

models diagram no. system suspension version
system
81.99116. with without BL/ LL/
BLL LLL
ECAS with Truck
4x2 8133 07. 02 X X raising/ 6.11-1 Semitrailer
FL/FLL Sheet 1 lowering Tipper
ECAS with Truck
4x2 8133 09. 00 X X raising/ 6.11-2 Semitrailer
FL Sheet 2 lowering
Truck and
4x2 8134 02. 01 X X 6.13-1 semitrailer
FLL Sheet 1
ECAM
4x2 8134 07. 01 X X under 6.13-2 Truck and
FLL Sheet 2 battery box semitrailer
ECAS with
6x2 8135 07. 02 X X raising/ 6.15-1 Truck
FLL Sheet 1 lowering Semitrailer
and lifting
axle
6x2 ECAS with
FNL 8135 07. 02 X X raising/ 6.15-2 Truck
Sheet 2 lowering
and lifting
axle
ECAS with
FNLL Sheet 1 lowering
and lifting
axle
ECAS with
FNLL Sheet 2 lowering
and lifting
axle
With non-
6x2 8137 01. 02 X X lifting 6.19-1 Truck
FPL Sheet 1 leading Semitrailer
axle
With lifting
6x2 8137 01. 02 X X leading 6.19-2 Truck
FVL Sheet 2 axle Semitrailer
6x4 8141 04. 02 X X 6.21-1 Truck

FDL/FFDL Sheet 1 Semitrailer
RA - P 85 6.10 -1
KEY TO AIR SUSPENSION INSTALLATION DIAGRAMS
Air suspension system installation diagram no. 81.99116.8133 Sheet 1, as of 07. 02, for model
18.XXX FL, trucks/tippers/semitrailers with ECAS
(raising/lowering)
Key: Semitrailer (FL)
G 73.221 Solenoid valve (ECAS)

008 Line from air reservoir to air suspension (see brake system installation diagram)
025 See brake system installation diagram
026 See installation drawing, test connections on battery box
030 Lines visible on brake system installation diagram
2) Service brake, rear axle (service brake system)
3) Parking brake (parking brake system)
Key: Truck/Tipper (FL)

027 See installation drawing, test connections on rear axle
6.10 - 2 RA - P 85
AIR SUSPENSION INSTALLATION DIAGRAM
Air suspension system installation diagram no.: 81.99116.8133, Sheet 1, as of 07.02, Heavy Range semitrailers, trucks and tippers, model 18.XXX FL, version with ECAS (raising and lowering).
RA - P 85 6.11 - 1
KEY
Air suspension system installation diagram no. 81.99116.8133 Sheet 2, for model 18.XXX FL, trucks/
tippers/semitrailers with ECAS (raising/lowering), ECAM
under battery box
Key: Semitrailer (FL)

1) Service brake, front axle left
21) Reservoir, circuit 1
24) Reservoir, auxiliary consumers
RA - P 85 6.12 -1
Air suspension system installation diagram no.: 81.99116.8133, Sheet 2, as of 09.00, Heavy Range semitrailers, trucks and tippers, model 18.XXX FL, version with ECAS (raising and lowering), ECAM under battery box.
6.11 - 2 RA - P 85
KEY
Air suspension system installation diagram no. 81.99116.8134 Sheet 1, as of 02. 01, for model
18.XXX FLL, trucks/semitrailers
Key: Semitrailer / Truck (FLL)

6.12 - 2 RA - P 85
Air suspension system installation diagram no. 81.99116.8134 Sheet 1, as of 02. 01, for model 18.XXX FLL, Heavy Range trucks and semitrailers.
RA - P 85 6.13 - 1
KEY
Air suspension system installation diagram no. 81.99116.8134 Sheet 2, for model 18.XXX FLL,
trucks and semitrailers with ECAM under battery box
Key: Semitrailer/Truck (FLL)

1) Service brake, front axle left
24) Reservoir, auxiliary consumers
RA - P 85 6.14 -1
Air suspension system installation diagram no.: 81.99116.8134, Sheet 2, as of 07.01, trucks and semitrailers, model 18.XXX FLL, version with ECAM under battery box.
6.13 - 2 RA - P 85
KEY
Air suspension system installation diagram no.: 81.99116.8135 Sheet 1, as of 07. 02, for model
26.XXX FNL, trucks and semitrailers with ECAS (raising
and lowering) and lifting axle.
Key: Truck/Semitrailer (FNL)

G 5.7 Pressure limiting valve
G 22.62 Quick-release valve, low-noise, connection 3 = M 22 x 1.5
G 27.67 Silencer
4) Service brake, trailing axle
6.14 - 2 RA - P 85
Air suspension system installation diagram no.: 81.99116.8135 Sheet 1, as of 07. 02, Heavy Range trucks and semitrailers, model 26.XXX FLL, version with ECAS (raising and lowering) and lifting axle.
RA - P 85 6.15 - 1
KEY
26.XXX FNL, trucks and semitrailers with ECAS
(raising and lowering) and lifting axle.
Key: Truck/Semitrailer (FNL)

G 15.11 Pressure ratio valve (transducer 1.15:1)
G 23.61 Check valve
G 23.204 Check valve
G 24.9 Vent valve, pneumatically controlled (3/2-way valve, Europe valve)
G 27.67 Silencer
024 Connector, see pipe list
028 With ECAM: inserted in G 25.F. Without ECAM: inserted in G 4.F connection 1
RA - P 85 6.16 -1
Air suspension system installation diagram no.: 81.99116.8135 Sheet 2, as of 07. 02, Heavy Range trucks, model 26.XXX FNL, version with ECAS (raising and lowering) and lifting axle.
6.15 - 2 RA - P 85
KEY
26.XXX FNLL, trucks and semitrailers with ECAS
(raising and lowering) and lifting axle
Key: Truck/Semitrailer (FNLL)

G 23.1 Check valve
G 27.67 Silencer
024
028 PA 9 x 1.5 - pipe list, battery box - 7, for ECAM - 6
029
6.16 - 2 RA - P 85
Air suspension system installation diagram no.: 81.99116.8136 Sheet 1, as of 07. 02, Heavy Range trucks, model 26.XXX FNLL, version with ECAS (raising and lowering) and lifting axle.
RA - P 85 6.17 - 1
KEY
26.XXX FNLL, trucks and semitrailers with ECAS
(raising and lowering) and lifting axle
Key: Truck/Semitrailer (FNLL)

G 15.11 Pressure ratio valve (transducer 1.15:1)
G 23.1 Check valve
G 23.204 Check valve
G 24.9 Vent valve, pneumatically controlled (3/2-way valve, Europe valve)
G 27.67 Silencer
028 With ECAM: inserted in G 25.F. Without ECAM: inserted in G 4.F connection 1
RA - P 85 6.18 -1
Air suspension system installation diagram no.: 81.99116.8136 Sheet 2, as of 07. 02, Heavy Range trucks, model 26.XXX FNLL, version with ECAS (raising and lowering) and lifting axle.
6.17 - 2 RA - P 85
KEY
26.XXX FPL, trucks and semitrailers with non-lifting
leading axle.
Key: Truck/Semitrailer (FPL)

G 23.1 Check valve
G 27.67 Silencer
6.18 - 2 RA - P 85
Air suspension system installation diagram no.: 81.99116.8137 Sheet 1, as of 01. 02, Heavy Range trucks and semitrailers, model 26.XXX FPL, version with ECAS (raising and lowering) and non-lifting leading axle.
RA - P 85 6.19 - 1
KEY
26.XXX FPL, trucks and semitrailers with lifting leading
axle.
Key: Truck/Semitrailer (FPL)

G 27.67 Silencer
RA - P 85 6.20 -1
Air suspension system installation diagram no.: 81.99116.8137 Sheet 2, as of 01. 02, Heavy Range trucks and semitrailers, model 26.XXX FVL, version with ECAS (raising and lowering) and lifting leading axle.
6.19 - 2 RA - P 85
KEY
26.XXX FDL/FFDL, trucks and tippers.
Key: Truck/Tipper (FDL/FFDL)

6.20 - 2 RA - P 85
Air suspension system installation diagram no.: 81.99116.8141 Sheet 1, as of 04. 02, Heavy Range trucks and semitrailers, model 26.XXX FDL/FFDL.
RA - P 85 6.21 - 1
OVERVIEW, AIR SUSPENSION FUNCTION DIAGRAMS
Air suspension function diagrams

Overview for
- 2, 3 and 4-axle trucks (Heavy Range, TG-A)
- Pneumatically braked front, leading/trailing and rear axle
Model no. Vehicle Function Date Swap-body Air Remarks

models diagram system suspension
no. system
81.99115. with with- BL/ LL/ Special
out BLL LLL version
H05, H06, 4x 2
H07, H61, 18.xxx FL 8193 03. 00 X X Semitrailer 6.51-1
H05, H07, 4x 2
H70, 18.xxx FL 8194 03. 00 X X Truck/ 6.51-2
semitrailer
H09, H12, 4x 2
H14, 18.xxx FLL 8195 03. 00 X X Truck/ 6.52-1
semitrailer
6x2 Truck/
H16, H17, 26.xxx 8196 14. 09. 00 X X semitrailer 6.52-2
H27, H88, FNL/FNLL with lifting
axle
6x2 Truck/
H19, H20, 26.xxx 8197 14. 09. 00 X X semitrailer 6.53-1
H31, H44, FNL/FNLL with lifting
axle
Truck/
H23, H32, 6x2 8198 14. 09. 00 X X semitrailer 6.53-2
26.xxx with non-
FPL/FVL lifting leading
axle
6x2 Truck/
H23, H32, 26.xxx 8199 02. 01 X X semitrailer 6.54-1
FPL/FVL with lifting
leading axle
6x4 Truck/
H29, H40, 26.xxx 8200 05. 01 X X semitrailer 6.54-2
FDL/FFDL with double
driven axle
Heavy-duty
H95, 8 x 4/4 82.99115- 03. 02 X X tractor, 6.55-1
41.xxx FVD/L 8131 leading axle
liftable
RA - P 85 6.50 -1
AIR SUSPENSION
Electronic level control (ECAS) for vehicles with air suspension
Raise Lower
(1) Position sensor (6) Switch

(2) Solenoid valve (7) ALB - pressure sensor
(3) ECU (electronic control unit) (8)
(4) Remote control (lowering, raising, stop) (9) Air bellows
(5) Test connection
001 From compressed air reservoir, air 002 From connection 24, multi-circuit protection
suspension valve
Electronic level control (ECAS) offers the following advantages for vehicles with air suspension:
Horizontal vehicle body at specified level, even if load is unevenly distributed.
Constant level without manual adjustment when using loading ramp/dock.
Quick raising and lowering.
Only a small amount of air is required as brief dynamic spring movements have no effect on the control
process.
Compact installation space
Advantages of ECAS versus conventional air suspension control:
All control processes performed at high speed due to large nominal width.
Damping minimises air consumption.
No control due to dynamic wheel load shift when cornering.
Easy to use thanks to remote control.
Optimal loading ramp/dock operation thanks to automatic level adjustment (only when air supply is
assured).
High degree of control accuracy.
Adjustable height and depth limits.
Locking of remote control as a function of road speed.
Easy installation, small amount of piping required, compact design.
Warning when driving with level = normal level.
Malfunction indicator and diagnosis capability.
6.50 - 2 RA - P 85
FUNCTION DIAGRAM
Air suspension system function diagram no.: 81.99115.8193, as of 03.00, Heavy Range trucks, type 18.XXX FL, 4 x 2 semitrailers (BL), version with ECAS
(3)
(3)
G73.221
(Y132)
21
22
23 G54.X
11
3
G74.301
(B129)
(3)
(3)
(3)
81.99115.8193
Key:
G 54.X Test connection
G 73.221 Electro-pneumatic solenoid valve (ECAS)
G 74.301 Position sensor for electronically controlled air suspension
001 Line from air reservoir, see brake function diagram
003 Air bellows, driven axle
See electrical diagram
RA - P 85 6.51 - 1
FUNCTION DIAGRAM
Air suspension system function diagram no.: 81.99115.8194, as of 03.00, Heavy Range 4 x 2 trucks/semitrailers (BL), model 18.XXX FL, version with ECAS.
G74.301
(B130)
(3)
(3)
G73.220
(Y132)
21
22
G54.X
23
11
(3)
(3)
(3)
G74.301
(B129)
81.99115.8194
Key:
G 73.220 Electro-pneumatic solenoid valves (ECAS)
6.51 - 2 RA - P 85
FUNCTION DIAGRAM
Air suspension system function diagram no.: 81.99115.8195, as of 03.00, Heavy Range 4 x 2 trucks/semitrailers (LLL), model 18.XXX FL/FLL, version with ECAS.
G74.301
(B130)
(3)
G54.X
(3)
(3)
G74.301 G73.240
(B128) (Y132) 3
26 22
27 23
11
G54.X G54.X
(3)
(3)
(3)
(3)
G74.301
(B129)
81.99115.8195
Key:
002 Air bellows, front axle
RA - P 85 6.52 - 1
FUNCTION DIAGRAM
Air suspension system function diagram no.: 81.99115.8196, as of 14.09.00, Heavy Range 6 x 2 trucks/semitrailers with lifting trailing axle (BLL), model 26.XXX FNL/FNLL, version with ECAS.
G57.300
(B201)
(3)
(3)
(3)
G74.301
(B130)
G5.7
7,4+0,2bar
G54.X
(3) 1 2
31
(3)
22 24
G73.230 25
(Y161)
G5.8
0,7-+0,1 bar
2 1
26 21 1 23 32 1
(3)
2 2
G22.62
3
G54.X G27.67
G54.X
(3) (3)
G74.301
(B129)
(3)
(3)
(3)
81.99115.8196
Key:
G 5.7 Pressure limiting valve with safety valve 12.5/7.4 + 0.2 bar 001 Line from air reservoir, see brake function diagram
G 5.8 Pressure limiting valve 10/0.7 0.1 bar 002
G 22.62 Quick-release valve, low-noise, connection 3 = M 22 x 1.5 003 Air bellows, driven axle
G 27.67 Silencer 004 Air bellows, trailing axle
G 54.X Test connection 005 Lifting bellows for trailing axle
G 57.300 Pressure sensor See electrical diagram
G 73.230 Electro-pneumatic solenoid valve (ECAS, rear axle/trailing axle)
6.52- 2 RA - P 85
FUNCTION DIAGRAM
Air suspension system function diagram no.: 81.99115.8197, as of 14.09.00, Heavy Range 6 x 2 trucks/semitrailers (LLL), model 26.XXX FNL/FNLL, version with ECAS with lifting trailing axle.
G57.300
(B201)
(3)
(3)
(3)
G74.301
(B130)
(3)
G5.7
7,4+0,2bar
G54.X (3) 1 2
31
(3)
(1) 22 24
G73.230 25
(Y161)
G74.301 22 12
G73.210
(B128) 23 14 G5.8
(Y162)
0,7-+0,1 bar
(1)
2 1
26 21 1 23 32 1
G54.X
(3)
2 2
G22.62
3
G54.X G27.67
(3)
(3)
(3) (3)
G74.301
(B129)
(3)
(3)
(3)
(3)
81.99115.8197
Key:
G 5.7 Pressure limiting valve with safety valve 12.5/7.4 + 0.2 bar 001 Line from air reservoir, see brake function diagram
G 5.8 Pressure limiting valve 10/0.7 0.1 bar 002 Air bellows, front axle
G 22.62 Quick-release valve, low-noise 003 Air bellows, driven axle
G 27.67 Silencer 004 Air bellows, trailing axle
G 54.X Test connection 005 Lifting bellows for trailing axle
RA - P 85 6.53 - 1
FUNCTION DIAGRAM
Air suspension system function diagram no.: 81.99115.8198, as of 14.09.00, Heavy Range 6 x 2 trucks/semitrailers (BLL), model 26.XXX FPL/FVL, version with ECAS with non-lifting leading axle.
G57.300
(B201)
(3)
(3)
(1)
G74.301
Z
(3)
(B130)
R1
P2
A
P1
R2
G54.X
31
22 24
G73.230 25
(Y161)
G5.1
+0,05
0,3 bar
-0,15
2 1
26 21 1 23 32 1
2 2
G54.X G22.62
3
G27.67
G54.X
(3) (3)
G74.301
(3)
(B129)
(3)
(3)
81.99115.8198
Key:
G 5.1 Pressure limiting valve with safety valve, 10/0.3+ 0.05/ - 0.15 bar 001 Line from air reservoir, see brake function diagram
G 22.62 Quick-release valve, low-noise, connection 3 = M 22 x 1.5 002 Air bellows, leading axle
G 24.9 Vent valve, pneumatically controlled (Europe valve) 003 Air bellows, driven axle
Connection "A" and "R1,P2", see brake function diagram 004 Connection "A" and "R1,P2", see brake function diagram
G 27.67 Silencer See electrical diagram
G 57.300 Pressure sensor
6.53 - 2 RA - P 85
FUNCTION DIAGRAM
Air suspension system function diagram no.: 81.99115.8199, as of 02.01, Heavy Range 6 x 2 trucks/semitrailers (BLL), model 26.XXX FPL/FVLL, version with ECAS with lifting leading axle.
G57.300
(B201)
(3)
(3)
G74.301
(3)
(B130)
(3)
G54.X
31
22 24
G73.230 25
(Y161)
G5.1
+0,05
0,3 bar
-0,15
2 1
26 21 1 23 32 1
2 2
(3)
G22.62
3
G27.67
G54.X G54.X
(3) (3)
G74.301
(3)
(B129)
(3)
(3)
81.99115.8199
Key:
G 5.1 Pressure limiting valve with safety valve, 10/0.3 + 0.05/ - 0.15 bar 001 Line from air reservoir, see brake function diagram
G 22.62 Quick-release valve, low-noise, connection 3 = M 22 x 1.5 002 Air bellows, leading axle
G 27.67 Silencer 003 Air bellows, driven axle
G 54.X Test connection 005 Lifting bellows for leading axle
RA - P 85 6.54 - 1
FUNCTION DIAGRAM
Air suspension system function diagram no.: 81.99115.8200, as of 05.01, Heavy Range 6 x 4 trucks/semitrailers (BLL), model 26.XXX FDL/FDDL, version with ECAS.
(3) (3)
(3)
G74.301
(B130)
(3)
G73.220
(Y132)
21
22
G54.X
23
11
(3)
(3)
G74.301
(B129)
(3)
(3) (3)
81.99115.8200
Key:
G 54.X Test connection 001 Line from air reservoir, see brake function diagram
G 73.220 Electro-pneumatic solenoid valve (ECAS) 002 Air bellows, driven axle I
G 74.301 Position sensor for electronically controlled air suspension 003 Air bellows, driven axle II
6.54 - 2 RA - P 85
FUNCTION DIAGRAM
Air suspension system function diagram no.: 82.99115.8131, as of 03.02, Heavy Range 8 x 4/4 trucks/semitrailers (LLL), model 41.XXX FVD/L (H95), version with air suspension and leading axle, leading axle liftable.
Key:
G 5.1 Pressure limiting valve 10/0.3 -0.2 bar G 62.201 Solenoid valve, air out (3/2-way valve) NW 4
G 5.205 Pressure limiting valve 12/8.0 -0.2 bar G 69.1 Control valve for air springs, load-controlled
G 21.200 Shuttle valve with return flow, piston valve with shackle 001 Switch, empty run or lifting
G 23.3 Non-return valve 002 Relay, starting-off aid
G 50.... Compressed air reservoir 003 Switch, starting-off aid
G 50.64 Compressed air reservoir, 1l EC, 12.5 bar 004 Test connection pulled on test connection plate
G 51.... Drain valve 005 Test connection in frame
G 51.3 Drain valve with pin, without ring 006 ALB sensor (see brake function diagram)
G 54.X Test connection 007 Shut-off, brake, leading axle
G 55.17 Pressure switch, pneumatic, NO contact, 7.7 - 0.4 bar 008 Air bellows, leading axle
G 55.25 Pressure switch, pneumatic, NC contact, 4.7 - 0.4 bar V Reservoir, air suspension
G 57.... ALB sensor for electr. controlled air suspension (see brake function diagram) See electrical diagram
G 61.202 Solenoid valve, air in (3/2-way valve)
G 62.... Solenoid valve, air out (3/2-way valve)
RA - P 85 6.55 - 1
PLASTIC PIPES, PLUG-IN CONNECTIONS / SCREW CONNECTIONS
Plug-in Connections
VOSS System 232
Plastic Pipes,
Plug and Pipe Fittings
Note:
The description and illustration of the following brake units are based on data provided by the
manufacturer.
If brake devices are not described, this means that no documents were available for them at the time of
going to press.
These devices will be dealt with in a later edition of the manual.
10.2002
RA - P 85 7.00 -1
Plastic pipes and plug-in connections
Plastic pipes
Instead of steel pipes, plastic pipes made from polyamide are used
for the compressed air system lines (low-temperature side) in trucks,
buses and coaches. Voss plug-in connection system 232 is used for
connecting the lines.
Plastic pipes are not susceptible to corrosion, vibration and frame
distortion. Compared to metal pipes, they are easier to work with and
easier to route.
Vehicles with plastic pipes are identified with the warning sign
illustrated.
Assembly and repair
Assembly
Only plastic pipes to DIN 74324 Part 1 are used. Genuine MAN
spares conform to this standard. Due to the high temperatures
involved, do not attach plastic pipes to metal pipes which are
connected to the engine, air compressor, heater or radiator.
Keep the parts at least 200 mm away from parts of the exhaust
system.
Only high-grade steel pipes are allowed to be routed between

the air compressor and the air dryer and the pressure regulator
or drain tank.
IMPORTANT!
Remove plastic lines before starting repairs or welding work.
Perform visual, function and effectiveness checks after carrying out any repair work involving
loosening connections or replacing parts. These checks must be made in accordance with the safety
inspection directive ( 29 of the statutory regulations governing special inspections in the FRG).
In particular, check the circuit division after replacing parts whose connections can be swapped over
without a brake system malfunction becoming immediately apparent, e.g. the multi-circuit protection valve.
Route plastic pipes so as to prevent chafing, twisting, tensile stress and kinks.
The pipes contract at cold temperatures, so include an additional length of about 1% when routing them.
This amounts to an extra 10 mm for a 1-metre pipe.
If plastic pipes are routed in curves, the smallest permitted bending radii r (mm) are listed below:
Pipe r Pipe r Pipe r
4x1 20 9 x 1.5 50 14 x 2 80
6x1 30 11 x 1.5 55 16 x 2 100
8x1 50 12 x 1.5 65
Use elbow connections if smaller radii are necessary.
Important!
Heating of the pipes whilst routing is not permitted!
Fabric pipes may not be replaced by plastic pipes.
RA - P 85 7.00 -3
VOSS connection system 232

Single-section disconnectable version
230 Profiled bore 2 engagement stages Reliable fault Plug-in force control
- Full compatibility - No sudden opening if detection - Soft plugging-in with
with industry standard incorrectly inserted - Deliberate leakage in large excess travel
- No chance of confusing - 2-stage metal/plastic element 1st engagement stage - Balancing of production
with 230 with precisely guided metallic - No unintentional tolerances
- Reservoir connections retaining clips. sealing in the 1st
without profiled bore - Lower costs due to omission engagement stage due
inserts possible. of checking during assembly. to precisely defined
- Mechanical locking of the leakage channels
metal clips
Space for notes and details of new features/modifications
7.00 - 4 RA - P 85
PLUG-IN CONNECTIONS, DESCRIPTION, SYSTEM 232
Plug-in connection system 232
Plug-in connections
Plug-in connections allow fast connecting of plastic pipes. Only a spanner is necessary for disconnecting
them.
The permitted operating pressure is 13 bar in a temperature range from -40 C to +100 C.
The plug-in connection consists of the following

components: 4
1 Connector with sealing rings 5

2 Union screw with sealing ring
3 Locating ring
4 Retaining clips 3
5 Clip cage
The connector has a wide retaining groove 1 into

which both retaining clips engage. Two further 1
grooves hold sealing rings. The first sealing ring 2
seals against the compressed air medium. The
second sealing ring 3 prevents impurity ingress.
The special shape of the groove places axial
preload on the connector after the retaining clips
have engaged. The machined shoulder 4 of the
connector above the outer sealing ring helps to
stabilise the coupling unit and ensure that the
connector is fitted the right way (visual check). 2
4 3
The two-stage retaining element is clipped onto

the locating ring 4 at the union screw 2 . The 1
retaining element consists of the clip cage 3 and
the two retaining clips 1 .
2
The retaining clips are made of spring steel and
open on one side. They are widened by the cone
profile of the connector during assembly. They
engage in the retaining groove one after the other
after the connector has been inserted. 4
The union screw is screwed firmly into the brake 3

unit. A sealing ring seals off the screw-in thread.
RA - P 85 7.10 - 1
PLUG-IN CONNECTIONS, DESCRIPTION, SYSTEM 232
1 Connector with cone

2 Dirt seal and visual assembly check 1
3 Union screw
4 Connector sealing ring
5 Clip cage
6 Retaining clip 1
7 Unit
8 Locating ring
9 Retaining clip 2
10 Thread sealing ring 2
10
3
4
9
8 5
6
7
The line and unit are connected by pushing the

connector into the coupling unit. 1 2
The connector then engages with a two-stage
retaining element which is pushed from the plugged-
in position to the locking position by the axial
preload force and applied compressed air after the
second engagement stage 1 is reached.
If the second engagement stage is not reached, the
connection is still locked once the first engagement 3
stage 2 has been reached. In this position, there is
a deliberate gap 3 left so that a noise is heard
when the connector is incorrectly inserted.
Plug-in connection system 232 is available in

nominal sizes 8 and 12.
7.10 - 2 RA - P 85
PLUG-IN CONNECTION, REPAIRS, SYSTEM 232
Connector assembly
Securing the polyamide tubes

After repairs, attach the polyamide pipes using
plastic clamps at intervals of 500 to 800 mm as well
as at the start and finish of a curve. In the case of
pipe clusters, cable straps 1 can be used to tie
1
several pipes. The pipes must be attached so as to
allow changes in length caused by temperature
fluctuation.
Renew short lines in their entirety if they are

damaged. Cut out defective sections of longer lines
and join together using connecting nipples.
Cutting the polyamide pipe to length

Use plastic pipe cutters 1 to cut the polyamide pipe
to length. 1
When cutting to length, include an allowance of 1
cm per 100 cm (1%) of the line's length.
Place the pipe in the cutters
Press the blade against the pipe
Twist the pincer and pipe against each other until
the pincer cuts into the pipe
Cut through the pipe
All connectors are supplied with the plastic

protective cap 1 to prevent damage to the
connector journal. Do not remove the protective cap 1
2
until just before final assembly.
IMPORTANT
Press in at normal workshop temperature
Do not heat the polyamide pipe
The cone 2 of the connector must not be
damaged and must be clean and free of grease
The plastic pipe/cone connection must never be
secured using hose clamps or clamping sleeves
The inside diameter d4 of the polyamide pipe to be

mounted must correspond to the diameter d3 of the
cone in order to ensure the specified preload.
The dimension "a" corresponds to the length of the d1 Pipe d3 d4 a
cone. (mm) (mm) (mm) (mm) (mm)
NG 8 9.4 6x1 4.6 4.0 16

8x1/9x1.5 6.9 6.0 16
NG12 14.9 6x1 4.6 4.0 16
8x1/9x1.5 6.9 6.0 16
10x1.25 8.1 7.5 22
12x1.5 10.3 9.0 22
14x2 11.2 10.0 23
16x2 13.6 12.0 25
RA - P 85 7.20 - 1
PLUG-IN CONNECTION, ASSEMBLY, SYSTEM 232
Mounting connectors with grip pliers

1
The application force of the pipe clamping jaws can
be adjusted at the adjusting screw 1 .
The retaining elements can be changed in line with
the pipe diameter.
Place the polyamide pipe in the plastic pipe grip

pliers so that the pipe end protrudes approx.
2 mm on the non-chequered side
By hand, press the connector into the pipe end
as far as possible
Fit a suitable impact bushing 1 1
Use a plastic hammer to knock in the connector
until the cone is fully covered by the polyamide
pipe. The polyamide pipe must be against the
collar of the connector.
2mm
Assembly of T-pieces and connecting nipples

Mount the connecting nipple in the same way as
the connector
Place the second pipe end in the plastic pipe grip
pliers so that the pipe end protrudes approx.
2 mm on the non-chequered side
Remove the impact bushing
By hand, press the connecting nipple into the
pipe end as far as possible
Mount the impact tool 1
Knock the connecting nipple into the polyamide
pipe using the impact tool 1
2mm
7.20 - 2 RA - P 85
Mounting the union screw
Check that the entire connection bore is clean

before assembling in order to ensure safe and 1
reliable functioning.
Screw the new union screw 1 with greased

sealing ring into the assembly hole and tighten
by hand
Tighten the union screw using a single open-
ended spanner for screwed connections (12 Nm)
Connecting the connector and unit
Remove the protective cap from the connector

Grease the sealing rings on the connector with
"MAN 285 Li-PF 2" if necessary
Push the connector with fitted polyamide pipe
into the union screw
Press the connector against the dirt sealing ring
1 until both the retaining clips engage in the
connector groove
The plug-in connection is closed when the dirt
sealing ring 1 on the connector is no longer visible.
1
The first retaining clip engages as soon as the
slightest force is applied. The plug-in connection is
therefore secured against unintentional loosening.
The leak-tightness of the plug-in connection is
ensured when the second retaining clip engages.
Check that the plug-in connection is firmly

seated using testing tool 1 (30 N)
Disconnecting and re-assembling
IMPORTANT
Ensure that the line in question is depressurised
before disconnecting.
Unscrew the union screw (1)
RA - P 85 7.30 - 1
Pull the locating ring 1 off the union screw using

a suitable tool 2
Pull the retaining clips 2 out of the clip cage one
after the other using a suitable tool
Remove the clip cage 3 3
Pull the union screw off the connector
Exchanging individual parts

The individual parts of the plug-in connection show no signs of wear caused by operation.
Important!
However, always renew the union screw in its entirety following disassembly.
Renewing sealing rings

Carefully clean the groove beforehand
Lightly grease the new sealing ring with "MAN 285 Li-PF 2" and then fit it
Take care not to damage, stretch or twist the sealing ring
7.30 - 2 RA - P 85
SPECIAL TOOLS FOR PLUG-IN CONNECTION SYSTEM 232
Special tools for plug-in connection system 232
Fig. Item Designation MAN no.

Use Manufacturer no.
Cutters for plastic pipe 08.02350.9004
Plastic pipe grip pliers with retaining 80.99606.6057

elements
Impact tool DMR 10.5 80.99606.6076
Impact tool DMR 14.0 80.99606.6077

3
Impact tool DMR 16.5 80.99606.6078
Assembling T-plugs and
connecting nipples
Impact bushing DN 6 80.99606.0431

4 Assembling T-plugs and
connecting nipples
Single open-end spanner WAF 19 08.06003-9000

Plug-in connection union screw
RA - P 85 7.40 - 1
SPECIAL TOOLS FOR PLUG-IN CONNECTION SYSTEM 232



Crowfoot wrench ring WAF 19 3/8" 80.99603-0237
Crowfoot wrench ring WAF 24 3/8" 80.99603-0238

8 Plug-in connection union screw
Crowfoot wrench WAF 19 3/8" 80.99603-0242

7.40 - 2 RA - P 85
BRAKE UNITS, DESIGN AND FUNCTION
BRAKE UNITS, DESIGN AND FUNCTION
10.2002
RA - P 85 8.00 -1
MULTI-CIRCUIT PROTECTION VALVE
Device: Multi-circuit protection valve with throttle valve
Manufacturer: Manufacturer no.: MAN no.:
G no.: 4.201
Knorr ........................................................... AE 4609-II 37460 .................................. 81.52151-6095
Use
Installing multi-circuit protection valves in compressed air brake systems with several supply circuits
enables the pressure in each air reservoir to be protected individually. If one of the circuits fails, the
compressed air in the intact circuits is protected and, in the event of continued delivery from the air
compressor, the system is supplied with the protection pressure, which is equivalent to the opening
pressure.
EC Directive 98/12 stipulates that, if the system is partially charged, the parking brake may only be
released once the remaining braking effect (approx. 13%) is assured by the service brake.
Design
1 Energy inflow ................................ (M 22x1.5)

21 Energy outflow circuit 1 ................. (M 16x1.5)
3 Air out
A Throttle valve (EC valve)
a Ring area
b Circle area
1 Valve seat
2 Adjustment spring
3 Bypass
4 Bypass valve
5 Diaphragm
Operating pressure ............................. Max. 12 bar

Peak pressure ..................................... Max. 20 bar
Protection pressure ............................ 6.9 - 0.3 bar
Opening pressure, circuit 21, 22 & 24 6.9 - 0.3 bar
Opening pressure, circuit 23 .............. 7.0 - 0.3 bar
Closing pressure ................................ 4.5 + 0.5 bar
Operation
Filling position
The diaphragm (5) is divided into an outer ring area (a) and an inner circle area (b) by the valve seat (1).
The pressure is initially available at the ring area and raises the diaphragm against the adjusting spring (2)
(opening pressure).
The air compressor builds up a pressure equal to the opening pressure at the overflow valves 21 and 22. If
the nominal adjustment pressures are the same, the valve with the lower pressure is opened.
Both overflow valves for circuits 21 and 22 have bypass valves (4). At a pressure of 7 bar, these bypass
valves enable approx. 60 to 70 l/min of air to flow past the valve seats and into the circuits.
Whilst one circuit is filled via the open valve, air also flows into the 2nd brake circuit via the bypass. The
pressure in the brake circuit with the higher pressure is also available at circuits 23 and 24. If the opening
pressure for 23 and 24 is reached, the overflow valves open.
Due to the bypass and the pressure which has built up in the 2nd brake circuit as a result, the opening
pressure will fall in relation to the setting. Reason: the inner circle area (b) is energised by the reservoir
pressure and supports the pressure available at the ring area (a).
RA - P 85 8.10 - 1
Leaks in the vehicle - closing pressure
Dynamic closing pressure

Sudden pressure loss during driving (line break), air
compressor delivering.
The pressure in the defective circuit 21 or 22 falls
very quickly.
Air flows from the intact circuit to the defective
circuit
The pressure in the overflow valve falls to the
closing pressure which is lower than the opening
pressure. Due to the high flow speed in the system,
the pressure in the intact circuit is even higher than
in the valve, meaning that the dynamic closing
pressure is higher than the static closing pressure
with very slow pressure fall.
The overflow valve for the defective circuit closes
itself. The air compressor builds up an increasing
pressure in the valve.
Air flows into the open via the bypass valve (4) for
the defective circuit.
The delivery rate of the air compressor is greater
than the outflow via the bypass. The system is filled
up to the defective circuit opening pressure.
Protection pressure is applied in all intact circuits.
Sudden pressure loss during driving (line break), air compressor delivering.
The pressure in the defective circuit 21 or 22 falls very quickly.
Air flows from the intact circuit to the defective circuit
The pressure in the overflow valve falls to the closing pressure which is lower than the opening pressure.
Due to the high flow speed in the system, the pressure in the intact circuit is even higher than in the valve,
meaning that the dynamic closing pressure is higher than the static closing pressure with very slow
pressure fall.
The overflow valve for the defective circuit closes itself. The air compressor builds up an increasing
pressure in the valve.
Air flows into the open via the bypass valve (4) for the defective circuit.
The delivery rate of the air compressor is greater than the outflow via the bypass. The system is filled up to
the defective circuit opening pressure. Protection pressure is applied in all intact circuits.
Line break in circuit 21
When the engine is stopped and there is a line break in circuit 21, circuit 22 and 24 fall to protection
pressure. Circuit 23 falls to 0 bar.
If there is a line break in circuit 22, circuit 21 falls to protection pressure. If air from circuits 23 and 24 is
consumed, protection pressure is also applied here.
Line break in circuit 23 or 24
The system falls to the closing pressure and is then filled up to protection pressure (opening pressure of
the defective circuit).
Static closing pressure
Air compressor not delivering
One or more leaks cause air loss in the individual circuits.
In the event of a leak in circuit 21 or 22, the pressures are equalised until the overflow valves close and the
circuits are separated. The pressure in the defective circuit continues to fall whilst the static closing
pressure is maintained in the intact circuit.
In the event of a leak in circuit 23 or 24, all 4 circuits fall to their respective closing pressures whilst the
pressure in the defective circuit continues to fall until it reaches 0 bar.
8.10 - 2 RA - P 85
When the engine is stopped and there is a line break in circuit 21, circuit 22 and 24 fall to protection
pressure. Circuit 23 falls to 0 bar.
If there is a line break in circuit 22, circuit 21 falls to protection pressure. If air from circuits 23 and 24 is
consumed, protection pressure is also applied here.
Line break in circuit 23 or 24
The system falls to the closing pressure and is then filled up to protection pressure (opening pressure of
the defective circuit).
Static closing pressure

Air compressor not delivering
One or more leaks cause air loss in the individual circuits.

In the event of a leak in circuit 21 or 22, the pressures are equalised until the overflow valves close and the
circuits are separated. The pressure in the defective circuit continues to fall whilst the static closing
pressure is maintained in the intact circuit.
In the event of a leak in circuit 23 or 24, all 4 circuits fall to their respective closing pressures whilst the
pressure in the defective circuit continues to fall until it reaches 0 bar.
New function as per EC Directive

If the system is only partially charged, the parking
brake can only be released once the residual
braking power is reached by the service brake.
This is reached by means of a throttle valve (A)
through which air flows into the atmosphere from
circuit 23, thus reducing the pressure to 0 bar. This
valve is activated by brake circuit 21. When the
brake circuit falls to < 4.0 bar, the valve opens and
approx. 32 I/min (at a reservoir pressure of 8 bar)
flow into the open.
Behaviour in the event of line break
If a break occurs in circuit 21, the control pressure

for throttle valve A also falls to 0 bar and the valve
opens. In this case, the air compressor does not
only deliver via the bypass for the defective circuit, it also delivers into the open via the open throttle valve.
Behaviour during filling
The following can happen:

Firstly, circuit 22 is charged to 7 bar. Then circuits 21 and 23 open simultaneously or one shortly after the
other. The control pressure in circuit 21 is still below 4 bar whilst pressure build-up already starts in circuit
23. The EC valve has not yet closed and some air flows into the open. This leak is not important with
regard to the filling process. It does not constitute a system fault.
RA - P 85 8.10 - 3
Test
Circuit / connection I / 21 II / 22 III / 23 IV / 24
Opening pressure bar 6.9 - 0.3 6.9 - 0.3 7.0 - 0.3 6.9 - 0.3
Static closing pressure bar 4.5 4.5 4.5 4.5
Protection pressure bar 0 4.5 0 4.5
in the event of failure (0) bar 4.5 0 6.5 6.5
of circuits * bar 4.5 4.5 0 4.5
bar 4.5 4.5 4.5 0
* without re-delivery and at 0 bar in the defective circuit
8.10 - 4 RA - P 85
SERVICE BRAKE VALVE
Device: Dual-circuit service brake valve (EBS)
G no.: 7.304
Knorr ........................................................... 0 486 200 011 ....................................... 81.52130-6271
Use
When the service brake system is operated in electronically controlled brake systems (EBS), the foot brake
module generates the electrical setpoint for the electronic control unit (ECU). At the same time pneumatic
brake pressure is modulated for the back-up function.
Design
The foot brake module consists of a dual-circuit conventional service brake valve with a series-connected
or integrated brake power sensor (a).
Electrical connections
1 AGND Ground
2 SM1 Sensor voltage 1
3 SM2 Sensor voltage 2
4 Supply voltage
a Brake power sensor
Pneumatic connections
11 Energy inflow 1
12 Energy inflow 2
21 Energy outflow 1
22 Energy outflow 2
3 Air out
Operation
Driving
The reservoir pressure for both service brake

system circuits is effective at connections 11 and
12. The brake power sensor is connected to vehicle
ground at pin 1 of the electronic control unit and
receives a constant voltage supply of 5 volts from
the electronic control unit via pin 4.
Braking
When the service brake system is operated, two

potentiometers running in opposite directions are
activated, causing the output voltage to rise at pin 2 and fall at pin 3. The sum of the two voltages is
monitored and must remain within a specified tolerance band throughout the entire course of activation. A
signal line short-circuit is detected during braking, due to uneven protective resistances. The analogue
output at pin 2 can also be used for retarder activation. Each time the brakes are operated, connections
21 and 22 are ventilated in stages as in the case of conventional service brake valves.
RA - P 85 8.23 - 1
DIAPHRAGM BRAKE CYLINDER
Device: Diaphragm brake cylinder for disc brake
G no.: 10.302 right

WABCO ...................................................... 423 104 712 0 ....................................... 81.51101-6422
G no.: 10.303 left

WABCO ...................................................... 423 104 711 0 ....................................... 81.51101-6423
The listed cylinders cross sections illustrated are used for disc brakes with directly flange-mounted
diaphragm brake cylinders. These function in the same way as the previous design.
Description and figures: Knorr cylinder
Use
The diaphragm brake cylinder is used in compressed air brake systems, to generate the braking power for
wheel brakes. Thanks to its design, it has a lower inner friction than the piston cylinder. This produces a
more favourable response level and high resistance
to wear because there is no longer any friction
between the diaphragm and the housing.
Design
1 Diaphragm
2 Piston with piston rod
3 Plug for breather hole
4 Pressure spring
5 Piston rod
I Energy inflow
Cylinder - lower section mounting bolt .......M16x1.5

Tightening torque........................max: 180 + 30 Nm
Important
Always use a clamping device when

disassembling the cylinder.
The housing is highly spring-loaded!
Check that the push rod length is correct when
exchanging the brake cylinder.
Installation guideline
The diaphragm cylinder is installed on the disc brake calliper fitted to the axle by means of two mounting
bolts. The cylinder must be installed at an angle to the housing to prevent splash water ingress if the seal is
damaged. Make sure that the lower breather hole (3) in the housing is open and the remaining three holes
are plugged.
RA - P 85 8.26 -1
DIAPHRAGM BRAKE CYLINDER
Function and operation
Driving
The chamber (a) is depressurised. The pressure spring (4) holds the piston (2) and the diaphragm (1) in
their starting positions.
Braking
If the diaphragm (1) is pressurised with compressed air via the energy inflow (connection chamber a), the
resultant power acts on the piston (2) and the piston rod moves it to the left. Power is transmitted to the
wheel brake via the hinged brake lever in proportion to the pressurisation pressure. The diaphragm cylinder
power output depends on the pressurisation pressure and the effective diaphragm surface area. The size
of this area depends on the degree of bulging which is itself dependent on the stroke. When the brake
cylinder is depressurised, the pressure spring (4) moves the piston (2) and the diaphragm (1) back to their
starting positions.
The internal pressure is equalised with that of the atmosphere through the open hole (3) so that there is no
back pressure during actuation.
Maintenance
Regularly check the cylinder condition, attachment, sealing and stroke depending on the vehicle type and
field of application.
8.26 - 2 RA - P 85
COMBINATION BRAKE CYLINDER
Device: Combination brake cylinder (Tristop cylinder), for D-ELSA disc brake
G no.: 11.170, type 20/24"
WABCO ....................................................... 925 460 110 0 ....................................... 81.50410-6722
G no.: 11.171, type 20/24"

WABCO ....................................................... 925 460 160 0 ....................................... 81.50410-6723
Use:
Combination brake cylinders (combined spring-loaded diaphragm cylinders) consist of two linked cylinders
acting on one piston rod. The diaphragm cylinder fitted in front allows the service brake system to be
operated independently of the parking brake system.
Pneumatic pressure exerts preload on a powerful spring in the parking brake section to allow the vehicle to
be operated. If the pressure falls, e.g.
due to actuation of the parking brake
valve, the releasing spring actuates the
wheel brake. All combination brake
cylinders are fitted with an emergency
release device.
Design
11 Energy inflow - service brake sys.
12 Energy inflow - parking brake sys.
1 Piston rod (service brake section)
2 Service brake piston
3 Valve
4 Emergency release spindle
5 Spring actuator piston
6 Pressure spring (spring actuator
section)
7 Breather hole
8 Pressure spring (service brake
section)
9 Diaphragm
10 Seal (spring actuator section)
Cylinder lower section mounting bolt
M16x1.5; tightening torque max:
180 + 30 Nm
Important!
Always disassemble the cylinder using clamping device.
The housing is highly spring-loaded.
Operation:
Driving:
The service brake piston (2) is held in driving position by the pressure spring (8). The spring actuator piston
(5) is pressurised with compressed air via the connection 12 and moved against the pressure spring (6)
until the stop is reached - the brake is released.
Braking, service brake system:

If the diaphragm (9) is pressurised with compressed air via the connection 11 when the service brake
system is actuated, the service brake piston (2) with piston rod (1) moves against the pressure spring (8)
and actuates the disc brake via the lever. The power output depends on the applied pressure and the
effective diaphragm surface area. The size of this area depends on the degree of bulging which is
dependent on the stroke.
When connection 11 is depressurised, the pressure spring (8) pushes the service brake piston (2) with
diaphragm (9) back to its starting position. The internal pressure is equalised with that of the atmosphere
through the open hole (7).
RA - P 85 8.30 - 1
COMBINATION BRAKE CYLINDER
Braking, parking brake system:

If the pressure at connection 12 is reduced during braking, the preloaded pressure spring (6) moves the
spring actuator piston (5) and activates the disc brake via the piston rod (1).
The pressure in the spring chamber (a) is equalised via a hole in the piston rod with integrated valve (3).
See "Vent valve" section for further details.
Released position:
Connection 12 of the spring actuator is fully pressurised in the released position. This means the
pressurised piston (5) is able to preload the spring (6) and thus release the spring actuator.
At the same time, connection 11 of the diaphragm cylinder is depressurised and the service brake is
released.
Vent valve:
In valve (3), the pressure in the spring chamber (a) is equalised with that of the atmosphere via connection
11 and the service brake system pipelines. As a result, the spring chamber (a) is protected against dirt and
moisture deposits.
The valve (3) is designed (spring force and flow area) so it remains open during movement of the spring
actuator piston (5), as long as the service brake is not applied. The valve (3) does not close and prevent
impermissible pressure build-up in the spring chamber (a) until the service brake is activated (pressure at
connection 11).
Note:
Due to the design of the system, a blow-off noise can be heard at the relay valve or at the parking brake
valve if pressure is very slowly applied at connection 11 by actuating the service brake whilst the parking
brake is applied. This does not mean there is a leak, since it does not happen when the spring actuator
section is pressurised or when the service brake is activated in the "normal" way.
Leaking spring actuator piston:
The spring chamber (a) can be depressurised via the valve (3) when the seal (10) is damaged. This means
the spring actuator cylinder does not brake unintentionally (as long as there is sufficient air supply at
connection 12).
Damage to the seal (10) does not influence the service brake pressure (connection 11) because, if the
pressure in the spring chamber (a) is greater, it is reduced via the valve (3) and depressurisation of the
front-mounted device (service brake valve or brake power regulator).
Mechanical release device:
The device responds automatically as described if the compressed air for the spring actuator fails due to a
defect.
The spring actuator is equipped with a mechanical release device in order to cancel the braking effect if this
situation arises.
The brake can be released mechanically if the pressure in the spring actuator cylinder (connection
12) fails. Secure the vehicle to prevent it from rolling away and turn the release spindle (4)
anticlockwise using a spanner (WAF 24) until the brake is released.
Important!
Screw the release spindle (4) back into the cylinder after the damage has been repaired and tighten
to 30 + 10 Nm.
Maintenance
Regularly check the cylinder condition, fastening and stroke, depending on the vehicle and field of
application.
Important!
Always use a clamping device (if possible) when disassembling the combination cylinder as
the spring is highly preloaded and represents an accident risk. Check that the link length is
correct when exchanging the cylinder
RA - P 85 8.30 - 3
PRESSURE SENSOR
Device: Pressure sensor (EBS)
G no.: 57.300
Knorr ........................................................... 0 484 205 006 ....................................... 81.27421-0202
Use
The load sensors are used in electronically

controlled brake systems in order to sense the axle
load when the vehicle load changes.
Position sensors are used in vehicles with
mechanical suspension, whilst pressure sensors are
used in vehicles with air suspension.
Operation
The sensor is attached to the vehicle frame and

contains a pressure-sensitive measuring element
with a booster circuit. The pneumatic connection is
connected with the corresponding air bellows.
The axle load sensor is supplied with a voltage of
5 volts by the pressure control module. An analogue
output voltage is produced as a function of the
physical variable (pressure).
Maintenance
When renewing the pressure sensor, make sure

that the output voltage is set correctly in accordance
with the bellows pressure. Refer to the data
provided by the vehicle manufacturer.
RA - P 85 8.69 - 1
PRESSURE CONTROL MODULE
Device: Pressure control module, 1-channel PCM (EBS)
G no.: 67.302
Knorr ........................................................... 0 486 203 016 ....................................... 81.52106-6004
Use
The pressure control module (PCM) has the task of controlling the brake pressure in the connected brake
cylinders in accordance with control commands issued by the integrated electronic control unit.
Design
Pneumatic connections
1 Energy inflow
2 Energy outflow
3 Air out
4 Control connection
1 Back-up valve
2 Inlet valve
3 Outlet valve
4 Pressure sensor
5 Integrated electronic control unit
6 Relay piston
7 Inlet valve seat
8 Outlet valve seat
a Chamber above relay piston
Operation
The pressure control module consists of the relay

valve, silencer, solenoid valves (1,2,3) for the back-
up circuit (back-up valve), inlet and outlet valve,
pressure sensor (4) and integrated electronic control
unit (5). It is also the node for transmitting the
signals of the connected sensors (rpm sensor,
brake wear sensor) to the electronic control unit via
the brake CAN.
Driving
Connection 1 is pressurised with reservoir pressure.

Connections 2 and 4 are depressurised. The back-up valve (1) is open whilst the inlet solenoid valve (2)
and outlet solenoid valve (3) are closed.
Braking
If the service brake system is activated whilst the system is intact, the pressure control module starts
controlling the brake pressure by closing the back-up valve (1). The pressure applied at connection 4
therefore has no effect on braking. Depending on how the inlet solenoid valve (2) and outlet solenoid valve
(3) are activated, the pressure in the chamber (a) is changed or maintained. In accordance with these
pressures, the piston (6) opens or closes the outlet valve seat (8) or inlet valve seat (7), causing the
pressure at connection 2 to be adjusted. The pressure sensor (4) senses the modulated pressure.
Note
The inlet solenoid valve (2) and outlet solenoid valve (3) are also activated when the ABS / ASR is
activated.
RA - P 85 8.73 - 1
EBS failure
The back-up valve (1) remains open if EBS fails. Connection 2 is pressurised due to the pressure applied
at connection 4. In this case the pressure control module acts as a relay valve.
Maintenance
The pressure control module is maintenance-free. Should any repairs be required, only the silencer and the
sheet metal cover may be replaced. If there is any other form of defect, the pressure control module must
be replaced in its entirety.
Installation note
The pressure control module breather must be facing downwards.
8.73 - 2 RA - P 85
Device: Pressure control module, 2-channel PCM (EBS)
G no.: 67.303
Knorr ........................................................... 0 486 204 012 ....................................... 81.52106-6005
Use
The pressure control module (PCM) has the task of controlling the brake pressure in the connected brake
cylinders in accordance with control commands issued by the integrated electronic control unit.
Design
1 Energy inflow
21 Energy outflow 1
22 Energy outflow 2
3 Air out
4 Control connection
The 2-channel pressure control module groups together the functions of two 1-channel pressure control
modules in a single housing
There is only one CAN+U MO line
The electronic control unit for both channels is located on a PCB
The reservoir pressure is supplied via a single connection 1
The pneumatic back-up function is provided via a single connection 4
The load sensor is directly connected to the 2-channel pressure control module
Each channel has connections for 2 rpm sensors, 2 brake wear sensors and 1 load sensor
RA - P 85 8.74 - 1
Maintenance
The pressure control module is maintenance-free. Should any repairs be required, only the silencer and the
sheet metal cover may be replaced. If there is any other form of defect, the pressure control module must
be replaced in its entirety.
Installation note
The pressure control module breather must be facing downwards.
8.74 - 2 RA - P 85
ECAS SOLENOID VALVE
Device: ECAS solenoid valve
G no.: 73.40
WABCO ...................................................... 472 900 050 0 ....................................... 81.25902 -6118
G no.: 73.240
WABCO ...................................................... 472 900 057 0 ....................................... 81.25902 -6158
Use
This valve is used to create a so-called 2-point control system in which position sensors on both sides of
the axle are used to separately control the height of both vehicle sides, thus ensuring that the body remains
parallel to the axles, despite the uneven load distribution.
Grouping together several solenoid valves in a single, compact block minimises the installation space and
connection complexity. Activated by the ECU (acting as an actuator), the solenoid valves convert the
applied voltage into a pressurisation or depressurisation sequence, i.e. they increase, reduce or maintain
the volume of air in the air bellows. Valves with pilot control are used in order to ensure a high air flow rate.
The solenoids initially switch valves with low nominal width. Their control air is then forwarded to the piston
surfaces of the actual control valves (NW 10 or NW 7).
Design
11 Reservoir
21 Connection, solenoid valve,
2nd axle
22 Connection, air bellows
23 Connection, air bellows
1 Pilot control valve

2 Bore
3 Control piston
4 Connecting bore
5 Chamber
6 Valve plate
7 Bore
8 Bore
9 Control piston
10 Control piston
6.x Solenoid
Operation
The solenoid 6.1 switches a pilot control valve (1). This valve's control air acts on the vent/breather valve
control piston (3) via the bore (2). The pilot control valve is supplied via connection 11 (reservoir) and the
connecting bore (4). The drawing shows the vent/breather valve in the breather position in which the air
can flow out of the chamber (5) and to connection 3 via the bore of the control piston (3). When the
solenoid 6.1 is energised, the control piston (3) is pushed downwards. In this instance, the bore of the
control piston is initially plugged by the valve plate (6). The valve plate is then pressed down by its seat
(hence the name seat valve) so that air from the reservoir can flow into the chamber (5). The two other
valves connect the air bellows with the chamber (5). Depending on energisation of solenoids 6.2 or 6.3, the
control pistons (9) and (10) are energised via the bores (7) and (8) and open the valve plates (11) and (12)
to connections 22 and 23. A solenoid valve for controlling the second vehicle axle can be connected at
connection 21.
RA - P 85 8.78 - 1
ECAS POSITION SENSOR
Device: ECAS position sensor
G no.: 74.2
WABCO ...................................................... 441 050 006 0 ....................................... 81.25937 -0014
G no.: 74.200
WABCO ...................................................... 441 050 011 0 ....................................... 81.25937 -0016
Use
Position sensors are used to control the air suspension in buses, coaches and commercial vehicles. Their
task is to control the pressure in the air bellows in line with the vehicle load.
Operation
The sensor casing houses a coil in which an

armature is moved up and down. A connecting rod
connects the armature to a cam sitting on the shaft
of the lever. The lever is connected to the vehicle
axle. If the distance between the body and the axle
then changes, the lever is turned and, as a result,
the armature is moved into or out of the coil. The
coil inductivity therefore changes. The ECU
measures this inductivity at frequent intervals and
converts it into a distance value.
RA - P 85 8.79 - 1
TECHNICAL DATA, SPECIAL TOOLS
10.2002
RA - P 85 9.00 -1
TECHNICAL DATA
Technical data, general
Thermal application range : -40 C ... +70 C

Max. operating pressure : 14 bar
Burst pressure : > 25 bar
Max. flow rate when idling : 1000 l/min
Max. permitted backpressure when idling : < 1.5 bar
Medium : Air
Max. thermal load, not functioning : +80 C/1h
Heat output : 100 W max.
Degree of protection (ECU) : IP 66A-DIN 40050T9
Voltage : 16 - 32 VDC
Data bus : CAN
Additional interfaces : ISO 9141
Electrical plug connection : DIN 72 580
Max. permitted air inlet temperature : +65 C
Technical data for MAN-ECAM, part no. 310 013 ...

Pressure regulator shut-off pressure = 12.5 bar +/- 0.3 bar (8-13 bar parametric)
Pressure regulator operating range = 2 bar +/- 0.3 bar (0.6-2 bar parametric)
Back-up pressure regulator shut-off pressure = 12 bar +/- 0.3 bar (8-12 bar adjustable)
Back-up pressure regulator operating range = 2 bar +/- 0.3 bar
Equipment temperature when not functioning = +95 C max. / 18 h
Circuit pressure el. c. 21, 22, = 12.5 bar max. setting (^pressure regulator
shut-off pressure)
Circuit pressure el. c. 23, 23.1 = 8.5 bar max. adjustable
Circuit pressure el. c. 25 = 12.5 bar (pressure regulator shut-off pressure
8-13 bar parametric)
Circuit pressure, back-up c. 21, 22, 24, 25 = 12 bar (=shut-off pressure, back-up DR 8-12 bar
adjustable)
Circuit pressure, back-up c. 23 = 8.5 bar, 0/ -1 bar
Dyn. circuit protection pressure, el. c. 21-24 = 6.5 bar, 0/ +0.5 bar
Circuit protection pressure, back-up c. 21-24 = 7.5 bar, 0/ +1 bar
Safety valve, pressure regulator = 13.5 bar, 0/ +1.5 bar
Safety valve c. 23 / 23.1 = 8.6 bar, 0/ +0.4 bar
Mechanical circuit protection valve c. 21-25 = 6.5 bar, -0.6/+0.8 bar (6-8 bar adjustable)
Perm. pressure difference c. 23/23.1 = 0.3 bar 0.2 bar
ECU voltage supply U = 16-32 V DC
Current consumption without heating I = 250 mA 10%
Current consumption with heating I1 = 4.3 A 10%
Pin 1 = Term. 15
2 = K-line
3 = Not used
4 = Term. 31
5 = CAN-h
6 = CAN-L
7 = Not used
RA - P 85 9.10 -1
TECHNICAL DATA
Degree of protection with connector/cable = IP 66 A

Installation location = Protected from pressure and splash water, not
near the exhaust
Fastening/tightening torque, ECAM = 3xM 12x1.5 - lg, 50 Nm 3
have guaranteed free air access for cooling the
air dryer.
Air suspension: Operating pressure: 12.5 0.2 bar

Wheel brakes:
Front axle:
Vehicles above 15 t except MERITOR - D - ELSA disc brake 432 mm
construction site vehicles Drum brake 410 mm
Brake cylinders: Diaphragm cylinder See function

diagram
Construction site and all-wheel
drive vehicles above 15 t S-cam brake 410 mm
Rear axle:
Vehicles above 15 t except MERITOR - D - ELSA disc brake 432 mm
construction site vehicles Drum brake 410 mm
Construction site and all-wheel
drive vehicles above 15 t S-cam brake 410 mm
Brake cylinders: Combination brake cylinder (Tristop cylinder) See function
diagram.
Release pressure 5.8 bar
Brake calculation pressure 10.0 bar
9.10 - 2 RA - P 85
SPECIAL TOOLS
Special tools for plug-in connection system 230/232

Cutters for plastic pipe 08.02350.9004
Plastic pipe grip pliers with retaining 80.99606.6057

elements
Impact tool DMR 10.5 80.99606.6076
Impact tool DMR 14.0 80.99606.6077

3
Impact tool DMR 16.5 80.99606.6078
Assembling T-plugs and
connecting nipples

4 Assembling T-plugs and
connecting nipples
Assembly device NG12 80.99606.0394

For mounting spring element,
retaining clip and union screw
5
RA - P 85 9.15 - 1
SPECIAL TOOLS

Assembly device NG12 80.99606.0395

For mounting spring element,
retaining clip and union screw
6


Crowfoot wrench ring WAF 19 3/8 80.99603-0237
Crowfoot wrench ring WAF 24 3/8 80.99603-0238

9 Plug-in connection union screw
Crowfoot wrench WAF 19 3/8 80.99603-0242

10
9.15 - 2 RA - P 85
SPECIAL TOOLS

Test tool 80.99606.0399

Checking engagement of the
compressed air plug-in connection
11
RA - P 85 9.15 - 3
MAN Nutzfahrzeuge Aktiengesellschaft
Dachauer Str. 667
80995 MNCHEN
Repair Manual P 85,

2nd edition
Brake System and Air Suspension
Trucknology Generation A (TG-A)
- English -
Publication no. 81.99198-6032
Printed in Germany

Man Brake System and Air Suspension

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Man Brake System and Air Suspension

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Droits d'auteur :

Formats disponibles

Brake System and Air

Publication no.: Repair Manual

MAN Nutzfahrzeuge Aktiengesellschaft Reparaturanleitung P 85

Brake System and Air Suspension

2002 MAN Nutzfahrzeuge Aktiengesellschaft

Title page/printer's imprint ............................................................................................................... 1.10-1

Function diagrams ........................................................................................................................... 2.20-1

Supplementary function diagrams................................................................................................... 5.00-1

Installation and function diagrams, air suspension ......................................................................... 6.00-1

Overview of function diagrams, air suspension............................................................................... 6.50-1

Plastic pipes, VOSS - plug connections/screw connections ............................................................ 7.00-1

Brake units, design/function ............................................................................................................. 8.00-1

Technical data, special tools ............................................................................................................ 9.00-1

1.30 Safety regulations

Work performed on the brake system:

Collect any hydraulic/brake fluid that leaks out.

Only authorised personnel are permitted to start and operate an engine.

Always disconnect the batteries before working on the electrical system.

If paint spraying is to be carried out, do not expose the electronic components to

3. Limited liability for accessories and parts

Attachments and special bodies

Taking out of operation or putting into storage

4. Regulations for preventing damage to health and the environment:

Cleaning the cooling circuit

Cleaning the filter element

Used engine/gearbox oil

Health protection precautions

Take care to dispose of used engine/gearbox oil properly.

Extract from "Information on dealing with used engine oil"

5. Working on brake pads, brake linings and similar parts

If possible, use hand-operated or slow-running tools, equipped with a dust-collector if required!

If possible, wet the workpiece prior to cutting or drilling!

Dispose of brake pads or linings as hazardous waste in an environmentally sound manner!

ABS : Anti-lock brake system

LFA : Air suspension system

References to other repair manuals dealing with brake repairs:

1. ECAM Electronically Controlled Air Management, see description on page 1.40 - 1

Functional Description (ECAM):

1.1 ECAM - use

1.2 ECAM - features

ECAM comprises the following system components, all

ECAM controls and monitors the following functions/

1.3 ECAM - advantages

Freely programmable pressure regulator operating range

1.4 ECAM - meets requirements to:

ECE R13 - Annex 8

49 StVZO - Annex XXI (German licensing regulations)

1.5 ECAM - general requirements

Pressure regulator shut-off pressure : 8.5 - 12.5 bar

1.6 Technical data, general

Thermal application range : -40 C ... +70 C

Operating pressure = 14 bar max.

2. ECAM functional description - fig. 1

Fig. 1 Ignition off

2.1.2 Engine start (fig. 2)

Fig. 2 Speed < n idling; air compressor idling

2.1.3 Initial filling (fig. 3)

Fig. 3 Speed > n idling; initial filling

2.1.4 Filling sequence

2.2 Pressure limiting, circuit 23 and circuit 24

2.3 Pressure control

2.3.1 Pressure regulator shut-off

2.3.2 Operating range, pressure regulator activation

2.4. Regeneration (fig. 9 and 10)